61snc01_05 - engine mechanical - assembly

7/23/2019 61SNC01_05 - Engine Mechanical - Assembly

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SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If engine maintenance is required)

INTEGRATED MOTOR ASSIST (IMA) SYSTEM (If engine maintenance is required)

The Civic Hybrid SRS includes a drivers airbag in the steering wheel hub, a passengers airbag in the dashboard

above the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat

belt buckles, side curtain airbags in the sides of the roof, and side airbags in the front seat-backs. Information

necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( ) on the

contents page include or are located near SRS components. Servicing, disassembling, or replacing these items

requires special precautions and tools, and should be done only by an authorized Honda dealer.

To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal

or side collision, all SRS service work should be done by an authorized Honda dealer.

Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury

caused by unintentional deployment of the airbags and/or side airbags.

Do not bump or impact the SRS unit, front impact sensors, or side impact sensors when the ignition switch is ON (II),

or for at least 3 minutes after the ignition switch is turned OFF; otherwise, the system may fail in a collision, or the

airbags may deploy.

SRS electrical connectors are identified by yellow color coding. Related components are located in the steering

column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats,

in the roof side, and around the floor. Do not use electrical test equipment on these circuits.

IMA components are located in this area. The IMA is a high-voltage system. The high voltage cables and their covers

are identified by orange coloring. The safety labels are attached to high voltage and other related parts (see page 1-5).

You must be familiar with the IMA system before working around it. Make sure you have read the Service Precautions

in the IMA section before performing repairs or service (see page 12-3).

06/09/19 10:39:12 61SNC010_050_0001


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Engine Mechanical

Engine Assembly

......................................................................................................Cylinder Head . 6-1

........................................................................................................Engine Block . 7-1

....................................................................................Engine Lubrication . 8-1

........................Intake Manifold and Exhaust System . 9-1

................................................................

..........................................................

..............................................................................................

................................................................

..........................................................

..............................................................................................

Special Tools . 5-2

Engine Removal . 5-3

Engine Installation . 5-12Engine Mount Replacement . 5-22

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Ref. No. Tool Number Description Qty

5-2

Engine Assembly

Special Tools

07AAK-SNAA120 Universal Eyelet 2

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Special Tools Required

5-3

Engine Removal

Universal eyelet 07AAK-SNAA120

Front subframe adapter VSB02C000016

2006 Civic engine hanger VSB02C000025

Engine support hanger, A and Reds AAR-T-12566

: Available through Honda Tool and Equipment

Program, 1-888-424-6857

NOTE:

Use fender covers to avoid damaging painted

surfaces.

To avoid damaging wire and terminals, unplug the

wiring connectors carefully while holding the

connector portion.

Mark all wiring and hoses to avoid misconnection.

Also, be sure that they do not contact other wiring,

hoses, or interfere with other parts.

1. Make sure you have the anti-theft codes for the

audio system and navigation system (if equipped).

2. Remove the cowl cover and the under-cowl panel

(see page 20-135).

3. Relieve the fuel pressure (see page 11-356).

4. Secure the hood in the wide open position (support

rod in the lower hole).

5. Disconnect the negative cable from the battery first,then disconnect the positive cable.

6. Remove the battery and battery box.

7. Remove the engine cover.

8. Remove the resonator (see page 11-383).

9. Remove the intake air duct.

10. Remove the air cleaner assembly (see page 11-381).

(contd)

06/09/19 10:39:14 61SNC010_050_0004


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5-4

Engine Assembly

Engine Removal (contd)

C

B

A

A

B

A

A

B

A

11. Remove the harness clamp (A), then remove the

starter cable (B) and the ground cable (C).

12. Remove the powertrain control module (PCM)

cover (A), then remove the bolts (B).

13. Disconnect the PCM connectors.

14. Disconnect the engine wire harness connectors (A),then remove the harness clamp (B) on the left side

of the engine compartment.

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5-5

E

B

C

A

D

B

A

15. Remove the vacuum hose.

16. Disconnect the purge control solenoid valve

connector (A), then remove the clip (B).

17. Disconnect the purge joint from the clamp stay (C),

then remove the fuel pipe nut (D) and the purge

control solenoid valve stay bolts (E).

18. Remove the drive belt (see page 10-10).

19. Remove the radiator cap.

20. Raise the vehicle on the lift to full height.

21. Remove the front wheels.

22. Remove the engine undercover (A) and the splash

shield (B).

23. Loosen the drain plug in the radiator, and drain the

engine coolant (see page 10-6).

24. Drain the CVT fluid (CVTF) (see page 14-208).

25. Drain the engine oil (see page 8-10).

26. Lower the vehicle on the lift.

27. Remove the radiator (see page 10-13).

(contd)

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5-6

Engine Assembly


A

A

B

C

A

B

A

28. Remove the A/C compressor, then disconnect the

A/C compressor clutch connector (A) without

disconnecting the A/C hoses.

NOTE: Hang the A/C compressor with a rope.

29. Remove the steering wheel (see page 17-6).

30. Remove the steering joint cover nuts (A), then

remove the cover (B).

31. Lock the steering wheel. Make reference marks (A)

across the steering joint and steering gearbox

pinion shaft. Remove the steering joint bolt (B), and

disconnect the steering joint from the steering

gearbox pinion shaft (C).

32. Remove the center guide (A) (if equipped), and

discard it. The center guide is for factory assembly

use only.

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5-7

A

A

B

A

B

A

D

B

D

C

33. Remove the IMA motor power cable clamps (A),

then remove the bolt (B).

34. Remove the water bypass hose (A) and the heater

hoses (B).

35. Disconnect the IMA motor power cable connector.

36. Remove the shift cable (see page 14-234).

37. Disconnect the solenoid harness connector (A) and

the input shaft (mainshaft) speed sensor connector

(B), then remove the clamp (C).

38. Remove the IMA motor power cable mounting

bolts (D).


(contd)

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5-8

Engine Assembly


A

A

A

B

07AAK-SNAA120

VSB02C000025

AAR-T-12566 C

B

D

A

40. Remove the under-floor three way catalytic

converter (TWC).

41. Disconnect the front stabilizer link (see page 18-23).

42. Disconnect the suspension lower arm ball joints

(see page 18-18).

43. Remove the driveshafts (see page 16-4). Coat all

precision-finished surfaces with new engine oil. Tie

plastic bags over the driveshaft ends.

44. Disconnect the steering gearbox harness

connectors (A).


46. Install the universal eyelet (07AAK-SNAA120) to the

threaded hole (A) on the cylinder head with a

10 x 1.25 mm bolt (B).

47. Install the front leg assembly (A), hook (B), and

wing nut (C) from an A and Reds engine support

hanger (AAR-T-12566) onto the 2006 Civic engine

hanger (VSB02C000025). Carefully position the

engine hanger on the vehicle, and attach the hook

to the universal eyelet (D). Tighten the wing nut by

hand to lift and support the engine/transmission.

NOTE: Be careful when working around the

windshield.

Replace.

Replace.

Replace.

Replace.

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5-9

A

B

A

B

A

A B

C VSB02C000016

48. Make sure the hoist brackets are positioned

properly. Raise the vehicle on the lift to full height.

49. Remove the lower torque rod mounting bolts.

50. Note the reference marks (A) on both sides of the

subframe that line up with the body (B).

51. Loosen both mid stiffener mounting bolts (A) on

both sides.

52. Attach the front subframe adapter (VSB02C000016)

to the subframe by looping the strap (A) over the

front of the subframe, then secure the strap with

the stop (B), then tighten the wing nut (C).

(contd)

Replace.

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5-10

Engine Assembly


07AAK-SNAA120

A

B

B

A C

53. Raise the jack and line up the slots in the arms with

the bolt holes on the corner of the jack base, then

tighten the bolts.

54. Remove the four bolts securing the front subframe,

and lower the subframe.


56. Install the universal eyelet to the threaded hole (A)

on the cylinder head with a 8 x 1.25 mm bolt (B).

57. Attach a chain hoist (A) to the universal eyelet (B),

and the transmission hook (C). Lift up on the

engine/transmission until its securely supported

by the chain hoist, and remove the engine support

hanger and 2006 Civic engine hanger.

58. Remove the transmission mount bracket support

bolt and nuts.

Replace.

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5-11

A

B

59. Remove the ground cable (A), then remove the side

engine mount bracket (B).

60. Check that the engine/IMA motor/transmission is

completely free of vacuum hoses, fuel and coolant

hoses, and electrical wiring.

61. Slowly lower the engine/IMA motor/transmission

about 150 mm (6 in.). Check once again that all

hoses and electrical wiring are disconnected and

free from the engine/IMA motor/transmission, then

lower it all the way.

62. Disconnect the chain hoist from the engine/IMA

motor/transmission.

63. Raise the vehicle all the way, and remove the

engine/IMA motor/transmission from under the

vehicle.

Replace.

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Special Tools Required

5-12

Engine Assembly

Engine Installation

LOWER TORQUE ROD BRACKET 12 x 1.25 mm74 Nm(7.5 kgfm, 54 lbfft)

12 x 1.25 mm74 Nm(7.5 kgfm, 54 lbfft)

Universal eyelet 07AAK-SNAA120

Front subframe adapter VSB02C000016

2006 Civic engine hanger VSB02C000025

Engine support hanger, A and Reds AAR-T-12566

: Available through Honda Tool and Equipment Program, 1-888-424-6857

1. Install the lower torque rod bracket, and tighten the bolts to the specified torques.

Replace.

Replace.

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5-13

07AAK-SNAA120 A

B

A

B

07AAK-SNAA120

VSB02C000025

AAR-T-12566 C

B

D

A

2. Raise the vehicle on the lift, and position the engine

/IMA motor/transmission under the vehicle. Be sure

that they are properly aligned. Carefully lower the

vehicle until the engine/IMA motor/transmission is

properly positioned in the engine compartment.

Make sure the vehicle is not resting on any part of

the engine/IMA motor/transmission.

3. Attach a chain hoist (A) to the universal eyelet

(07AAK-SNAA120) and transmission hook (B).

Carefully raise the engine/IMA motor/transmission

with the chain hoist into place.

4. Install the universal eyelet to the threaded hole (A)

on the cylinder head with a 10 x 1.25 mm bolt (B).

5. Install the front leg assembly (A), hook (B), and

wing nut (C) from an A and Reds engine support

hanger (AAR-T-12566) onto the 2006 Civic engine

hanger (VSB02C000025). Carefully position the

engine hanger on the vehicle, and attach the hook

to the universal eyelet (D). Tighten the wing nut by

hand to lift and support the engine/transmission.

NOTE: Be careful when working around the

windshield.

(contd)

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5-14

Engine Assembly

Engine Installation (contd)

A

A B

C

VSB02C000016

14 x 1.5 mm103 Nm(10.5 kgfm,75.9 lbfft)

14 x 1.5 mm103 Nm(10.5 kgfm,75.9 lbfft)

6. Install the side engine mount bracket (A), then

loosely tighten the mounting bolts and nut.

NOTE: Reinstall the mounting bolts/support nuts in

the sequence given in the following steps. Failure

to follow this sequence may cause excessive noise

and vibration, and reduce bushing life.

7. Loosely tighten the transmission mount bracket

support bolt and nuts.

8. Remove the chain hoist and universal eyelet, then

raise the vehicle on the lift.

9. Set the front subframe adapter (VSB02C000016) to

the subframe by looping the strap (A) over the front

of the subframe, then secure the strap with the stop

(B), then tighten the wing nut (C).

10. Line up the slots in the arms with the bolt holes on

the corner of the jack base, and tighten the bolts,

then lift the subframe up to the body.

11. Loosely install the new subframe mounting bolts.

Replace. Replace.

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5-15

A

B

A

B

12 x 1.25 mm64 Nm(6.5 kgfm, 47 lbfft)

12 x 1.25 mm64 Nm(6.5 kgfm, 47 lbfft)

A

12 x 1.25 mm72 Nm(7.3 kgfm,53 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm, 40 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm,40 lbfft)

6 x 1.0 mm9.8 Nm(1.0 kgfm, 7.2 lbfft)

12. Align the front subframe reference marks (A) on the

body (B), as noted during removal. Then tighten the

bolts on the front subframe to the specified torque.

13. Remove the jack and the front subframe adapter.

14. Install mid stiffener mounting bolts on both sides.

15. Tighten the lower torque rod mounting bolts.


17. Tighten the side engine mount bracket mounting

bolts and nut in the numbered sequence shown.

18. Install the ground cable (A).

(contd)

Replace.

Replace.

Replace.

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5-16

Engine Assembly


12 x 1.25 mm73 Nm(7.4 kgfm, 54 lbfft)

12 x 1.25 mm73 Nm(7.4 kgfm, 54 lbfft)

A

A

C10 x 1.25 mm33 Nm(3.4 kgfm,25 lbfft)

D8 x 1.25 mm22 Nm (2.2 kgfm, 16 lbfft)

B

B

A

19. Tighten the transmission mount bracket support

bolt and nuts.

20. Remove the engine hanger and universal eyelet

from the engine.


22. Connect the steering gearbox harness connectors

(A).

23. Install a new set ring on the end of each driveshaft

then install the driveshafts. Make sure each ring

clicks into place in the differential and the

intermediate shaft.

24. Connect the suspension lower arm ball joints

(see page 18-18).

25. Connect the front stabilizer links (see page 18-23).

26. Install the under-floor TWC (A); use new gaskets (B),

new self-locking nuts (C) and new bolts (D).


Replace.

Replace.

Replace.

Replace.

Replace.

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5-17

C

D

B

A6 x 1.0 mm9.8 Nm(1.0 kgfm,7.2 lbfft)

A6 x 1.0 mm9.8 Nm (1.0 kgfm, 7.2 lbfft)

A

B

B

B


28. Install the IMA motor power cable mounting bolts

(A).

29. Install the clamp (B), then connect the solenoid

harness connector (C) and the input shaft

(mainshaft) speed sensor connector (D).

30. Install the shift cable (see page 14-234).

31. Connect the IMA motor power cable connector.

32. Install the water bypass hose (A) and the heater

hoses (B).

33. Install the mounting bolt (A), then install the IMA

motor power cable clamps (B).

(contd)

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5-18

Engine Assembly


C

A

B

8 x 1.25 mm28 Nm(2.9 kgfm, 21 lbfft)

6 x 1.0 mm9.8 Nm(1.0 kgfm, 7.2 lbfft)

A10 x 1.25 mm22 Nm(2.2 kgfm, 16 lbfft)

C10 x 1.25 mm22 Nm(2.2 kgfm, 16 lbfft)

B10 x 1.25 mm

22 Nm(2.2 kgfm,16 lbfft)

D

34. Align the reference marks (A) on the steering joint

and steering gearbox pinion shaft. Connect the

steering joint (B) to the steering gearbox pinion

shaft (C). Tighten the steering joint bolt.

35. Install the steering joint cover.

36. Install the steering wheel (see page 17-8).

37. Loosely install the A/C compressor mounting bolts

and the compressor through bolt in the numbered

sequence shown. Failure to follow this sequence

may reduce the life of the drive.

38. Tighten the A/C compressor mounting bolts (A, C),

then tighten the A/C compressor through bolt (B) to

the specified torque.

39. Connect the A/C compressor clutch connector (D).

40. Install the radiator (see page 10-13).


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5-19

A

B

D

C

E


B6 x 1.0 mm12 Nm (1.2 kgfm, 8.7 lbfft)

B

B

A

B

42. Install the splash shield (A) and the engine

undercover (B).


44. Install the drive belt (see page 10-10).

45. Install the purge control solenoid valve stay bolts

(A) and the fuel pipe nut (B), then connect the purge

joint to the clamp stay (C).

46. Install the clip (D), then connect the purge controlsolenoid valve connector (E).

47. Install the vacuum hose.

48. Install the harness clamp (A), then connect the

engine wire harness connectors (B) on the left side

of the engine compartment.

(contd)

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5-20

Engine Assembly


B


C

B

A

8 x 1.25 mm9 Nm(0.9 kgfm, 7 lbfft)

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

49. Connect the powertrain control module (PCM)

connectors.

50. Install the bolts (A), then install the PCM cover (B).

51. Install the harness clamp (A), then install the starter

cable (B) and the ground cable (C).

52. Install the air cleaner assembly (see page 11-381).

53. Install the intake air duct.

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5-21

54. Install the resonator (see page 11-383).

55. Install the engine cover.

56. Install the under-cowl panel and the cowl cover

(see page 20-135).

57. Install the front wheels.

58. Install the battery box and battery. Clean the

battery posts and cable terminals, then assemble

them, and apply grease to prevent corrosion.

59. Move the shift lever to each gear, and verify that

the A/T gear position indicator follows the

transmission range switch.

60. Inspect for fuel leaks. Turn the ignition switch

ON (II) (do not operate the starter) so the fuel pump

runs for about 2 seconds and pressurizes the fuel

lines. Repeat this operation two or three times, then

check fuel leakage at any point in the fuel line.

61. Refill the engine with engine oil (see page 8-10).

62. Refill the transmission with CVT fluid (CVTF)

(see page 14-208).

63. Refill the radiator with engine coolant, and bleed

the air from the cooling system with the heater

valve open (see step 8 on page 10-7).

64. Do the PCM reset procedure (see page 11-4).

65. Do the PCM idle learn procedure (see page 11-343).

66. Do the crankshaft position (CKP) pattern clear/CKP

pattern learn procedure (see page 11-4).

67. Inspect the idle speed (see page 11-342).

68. Inspect the ignition timing (see page 4-18).

69. Check the wheel alignment (see page 18-5).

70. Do the start clutch pressure calibration procedures

(see page 14-204).

71. If the IMA battery level gauge (BAT) displays no

segment, start the engine, and hold it between

3,500 rpm and 4,000 rpm without load (in Park or

neutral) until the BAT displays at least three

segments.

72. Enter the anti-theft codes for the audio system and

navigation system (if equipped).

73. Set the clock.

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Exploded View

5-22

Engine Assembly

Engine Mount Replacement

12 x 1.25 mm73 Nm(7.4 kgfm, 54 lbfft)

TRANSMISSION MOUNT SIDE ENGINE MOUNT

LOWER TORQUE ROD

12 x 1.25 mm64 Nm(6.5 kgfm, 47 lbfft)

10 x 1.25 mm38 Nm(3.9 kgfm, 28 lbfft)

12 x 1.25 mm73 Nm(7.4 kgfm, 54 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm, 40 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm, 40 lbfft) 12 x 1.25 mm

72 Nm(7.3 kgfm, 53 lbfft)

10 x 1.25 mm49 Nm(5.0 kgfm, 36 lbfft)

10 x 1.25 mm49 Nm(5.0 kgfm, 36 lbfft)

12 x 1.25 mm64 Nm(6.5 kgfm, 47 lbfft)

12 x 1.25 mm74 Nm(7.5 kgfm, 54 lbfft)

12 x 1.25 mm64 Nm(6.5 kgfm, 47 lbfft)

Replace.

Replace.

Replace.

Replace.

06/09/19 10:39:51 61SNC010_050_0023

61snc01_05 - engine mechanical - assembly

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