Don Bosco School

Engine and its components

An engine is complex unit in which different
components are assembled together, and fuel
is burned to produce power or energy. The
engine converts chemical energy (heat energy)
into mechanical energy, which is then utilised
for vehicular movement. There are different
processes of fuel combustion. When the fuel is
burned within the engine, it is called an Internal
Combustion (IC) engine, and when it is burned
externally and the produced steam is used for
the mechanical movement, it is called an
External Combustion (EC) engine. Nowadays,
automobile engines are quite economical due to
the developments taking place in the field of
internal combustion engine. On the basis of the
process of ignition,
the automobile engines are classified into spark ignition engine (petrol or gas) and compression ignition
engine (diesel). In an IC engine, the reciprocating motion of the piston is converted into rotary motion
of the crankshaft and the produced power is then transmitted to move
the vehicle. In case of a rotary engine or Wankel engine, the rotor rotates and completes the process
of combustion and produces the power, which helps the vehicular movement. The spark ignition engine
can be differentiated from the compression ignition engine as per the following factors.
(i) The type of fuel used.
(ii) The way the fuel enters in the combustion chamber.
(iii) The way in which fuel is ignited.
Spark Ignition Engine (Petrol or Gas Engine) The spark ignition engine uses a highly volatile fuel, such
as gasoline, which turns into vapour easily. The fuel is mixed with air before it enters in the combustion
chamber, and forms a combustible air-fuel mixture. This mixture then enters the cylinder and gets

compressed with the help of a piston. An electric spark is produced by the ignition system which ignites
the combustible air-fuel mixture. The combustible gases burn and expand, which forces the piston
downwards for generating power.

Compression Ignition Engine (Diesel Engine)

In the compression ignition engine or diesel engine, only fresh air enters the cylinder, which is
compressed to a very high pressure and temperature, which could go up to 1000 °F (538 °C). The
diesel is then injected or sprayed into the engine combustion chamber. This spray contains very fine
and tiny particles of diesel in an atomised form. The hot air or heat of compression ignites the fuel and
generates the power stroke.
 Don Bosco School

Components of an IC Engine

1. Cylinder: The cylinder or cylinder liner of an IC engine is fitted in the cylinder block, which is a
single casted unit and is considered to be the main body of an engine. The block has cylinder liners.
The piston reciprocates up and down from Top Dead Centre (TDC) to Bottom Dead Centre (BDC)
to generate power.

The cylinder liner and the cylinder block have to withstand very high pressure (about 70 bar) and
temperature (about 700 C) during power stroke. The material used for the cylinder block must withstand
such heat and also disperse it effectively. The cylinder block is well-designed with water passages to
remove the excess heat and separate oil passages are provided for the circulation of lubricating oil.
The top portion of the cylinder block is covered by the cylinder head. The crankcase is an integral part
of the cylinder block which houses the crankshaft and the lower portion

2. Cylinder Head: The cylinder head is also singlecasted unit and bolted to the top portion of the
cylinder block. The combustión chamber is a part of the cylinder head, where the combustion of gases
takes place.
The water passages are provided to remove the heat from the cylinder head. In latest engines, the
cylinder head also houses the camshaft which has the inlet and exhaust valves with supportive valve
mechanism. This provision is made to fix spark plug in SI engines and nozzle in CI engines. The lower
portion of the cylinder head is well-machined to ensure there Is no leakage Of gases.

Cylinder head gasket is usually cast as one piece and bolted to the top of the cylinder (engine block).
Copper and asbestos gaskets are provided between the cylinder and cylinder-head to obtain a gas-
tight joint. The charge enters the combustión chamber through The inlet valve connected to the inlet
manifold, and the exhaust gases are removed through the exhaust valves connected to the exhaust
manifold.

3. Piston and Piston Rings: Piston is a cylindrical unit, used to compress the charge during
compression
stroke and to transmit the gas force to the connecting rod and then to the crankshaft during power
stroke. The pistons of IC engines are usually made of aluminium alloy, which has high termal
conductivity and is light in weight. The material of piston must have the ability for higher heat transfer.

The piston moves up and down (from TDC to BDC) and assists in completing the engine cycle. The
piston rings are placed in the ring Groove and provide sealing between the piston and the cylinder liner,
thereby preventing the leakage of high pressure gases. These are made of special grade cast iron,
which retains its elastic property even at very high temperature. The upper piston rings are called the
compression rings and the lower piston rings are called the oiling or oil control rings

4. Connecting Rod: It is usually manufactured by using drop-forged steel. It is made in the shape of
‘I’ so as to reduce its weight and to withstand strength. Its small end is connected to the piston with the
help of gudgeon pin and the big end is connected to the crankpin with shell bearings.
It has a passage for the transfer of lubricating oil from the big end bearing to the small end bearing
(gudgeon pin). The major function of the connecting rod is to convert the reciprocating motion of piston
to the rotary motion of the crankshaft.
 Don Bosco School

5. Crank and Crankshaft: The crankshaft is

called the backbone of an engine because it
converts the reciprocating motion of piston into
the rotary motion of the crankshaft. The
crankshaft is a single casted unit and is made of
drop-forged Steel main journals which are placed
and supported in the crank case.
The main journal and connecting journals are
machined to a smooth finish to reduce friction
and shell bearings are used for smooth rotation
of crankshaft.
Front end of the crankshaft Will transmit drive to
the camshaft and also to the timing gear,
whereas the flywheel is bolted to the flange at
rear end of the crankshaft. Main journal of the crankshaft carries the oil passages to lubricate shell
bearings. In case of a single cylinder engine crank assembly is used, two crank webs are connected
with the crank pin, and crank webs shafts are press fitted in both. At one side of the shaft magneto is
fastened whereas clutch assembly is mounted to the other. The crank assembly is balanced
dynamically as well as statically for the smooth transmisión of power.
 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

COMPONENT LOCATION INDEX

Fig. 1: Locating Starting System Components

Courtesy of AMERICAN HONDA MOTOR CO., INC.

SYMPTOM TROUBLESHOOTING INDEX

SYMPTOM TROUBLESHOOTING INDEX (EXCEPT GX)
Symptom Diagnostic procedure Also check for

1. Check for loose battery terminals or connections.

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2. Test the battery for a low charge (see BATTERY

TEST ).
3. Check the starter (see STARTER CIRCUIT
TROUBLESHOOTING ).
4. Check the starter cut relay (see POWER RELAY
Engine does not Poor ground at
TEST ).
start (does not G101 (A/T) or
crank) 5. Check the transmission range switch (A/T) (see G401 (M/T)
TRANSMISSION RANGE SWITCH TEST ).
6. Check the clutch interlock switch (M/T) (see
CLUTCH INTERLOCK SWITCH TEST ).
7. Check the ignition switch or wire (see IGNITION
SWITCH (ALL EXCEPT HYBRID) ).
1. Check for PGM-FI DTCs (see GENERAL
TROUBLESHOOTING INFORMATION ).
2. Check the fuel pressure (see FUEL PRESSURE
TEST ).
3. Check for a plugged or damaged fuel line (see FUEL
LINE INSPECTION ).
Engine cranks, but
4. Check for a plugged fuel filter (see FUEL Fuel level in tank
does not start
PRESSURE REGULATOR REPLACEMENT ).
5. Check the throttle body (see THROTTLE BODY
TEST ).
6. Check for low engine compression (see ENGINE
COMPRESSION INSPECTION ).
7. Check for a damaged or broken cam chain.
1. Check for PGM-FI DTCs (see GENERAL
TROUBLESHOOTING INFORMATION ).
2. Check the fuel pressure (see FUEL PRESSURE
TEST ).
Engine is hard to 3. Check for a plugged or damaged fuel line (see FUEL
start LINE INSPECTION ).
4. Check for a plugged fuel filter (see FUEL
PRESSURE REGULATOR REPLACEMENT ).
5. Check for a restricted three way catalytic converter
(TWO or exhaust system.
1. Check for loose battery terminals or connections.
2. Test the battery for a low charge (see BATTERY
Engine cranks TEST ).
slowly 3. Check the starter for binding (see STARTER
OVERHAUL ).
4. Check for excessive drag in the engine.

SYMPTOM TROUBLESHOOTING CHART (GX)

Symptom Diagnostic procedure Also check for

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Engine does not start (does not 1. Check for loose battery terminals Poor ground at G101
crank) or connections.
2. Test the battery for a low charge,
refer to the BATTERY (ALL
EXCEPT HYBRID) .
3. Check the starter, refer to the
STARTER CIRCUIT
TROUBLESHOOTING .
4. Check the starter cut relay (see
POWER RELAY TEST ).
5. Check the transmission range
switch, refer to the
TRANSMISSION RANGE
SWITCH TEST .
6. Check the ignition switch or
wire, refer to the IGNITION
SWITCH (ALL EXCEPT
HYBRID) .
Engine cranks, but does not 1. Check for PGM-FI DTCs (see
start HOW TO USE THE HDS
(HONDA DIAGNOSTIC
SYSTEM) ).
2. Check the throttle body, refer to
the THROTTLE BODY
TEST .
3. Check for low engine
compression, refer to the
ENGINE COMPRESSION
INSPECTION .
4. Check for a damaged or broken
cam chain.
Engine is hard to start 1. Check for PGM-FI DTCs (see
HOW TO USE THE HDS
(HONDA DIAGNOSTIC
SYSTEM) ).
2. Check for a restricted three way
catalytic converter (TWC) or
exhaust system.
Engine cranks slowly 1. Check for loose battery terminals
or connections.
2. Test the battery for a low charge,
refer to the BATTERY (ALL
EXCEPT HYBRID) .
3. Check the starter for binding,
refer to the STARTER
PERFORMANCE TEST .
4. Check for excessive drag in the

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

engine.

CIRCUIT DIAGRAM

Fig. 2: Starting System - Circuit Diagram

Courtesy of AMERICAN HONDA MOTOR CO., INC.

STARTER CIRCUIT TROUBLESHOOTING

Special Tools Required

l Alternator, Regulator, Battery & Starter tester OTC3131*

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

*Available through the Honda Tool and Equipment Program 888-424-6857

NOTE: l Air temperature must be between 59 and 100°F (15 and 38°C) during
this procedure.
l After this inspection, you must reset the engine control module
(ECM)/powertrain control module (PCM). Otherwise, the ECM/PCM will
continue to stop the fuel injectors from operating.
l The battery must be in good condition and fully charged.

1. Connect the alternator, regulator, battery & starter tester (OTC3131) to the battery as shown.

NOTE: The probe is not used for battery testing.

2. Do the BATTERY TEST.

Does the display indicate GOOD or GOOD, LOW CHARGE?

YES - The battery is OK. Go to step 3.

NO - If the display indicates BAD BATTERY, replace the battery, then retest. If the display indicates
CHARGE & RETEST, charge the battery, then retest.

3. Connect the HDS to the data link connector (DLC) (see step 2 in HOW TO USE THE HDS
(HONDA DIAGNOSTIC SYSTEM) ).
4. Turn the ignition switch ON (II).
5. Make sure the HDS communicates with the vehicle and the ECM/PCM. If it doesn't, troubleshoot the
DLC circuit (see DLC CIRCUIT TROUBLESHOOTING ).
6. Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
7. Set the parking brake, then with the clutch pedal pressed (M/T model) or the shift lever in N or P (A/T
model), turn the ignition switch to START (III) to crank the engine.

Does the starter crank the engine normally?

YES - The starting system is OK. Go to step 15.

NO - Go to step 8.

8. Turn the ignition switch to LOCK (0).

9. Check the battery condition (see BATTERY TEST ). Check the electrical connections at the battery,
the negative battery cable to the body, the engine ground cables, and the starter for looseness and
corrosion. Then try cranking the engine again.

Does the starter crank the engine normally?

YES - Repairing the loose connection corrected the problem. The starting system is OK. Go to step
15.

NO - Based on the following symptoms, take the appropriate action:

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

If the starter will not crank the engine at all, go to step 10.
l

l If the starter cranks the engine erratically or too slowly, go to step 14.

l If the starter does not disengage from the flywheel or torque converter ring gear when you
release the key, replace the starter, or remove and disassemble it and check for the following:
¡ Starter solenoid and switch malfunction

¡ Dirty drive gear or damaged overrunning clutch

¡ Damaged flywheel ring gear (M/T) or torque converter ring gear (A/T).

10. Make sure the shift lever is in neutral (M/T model) or N or P (A/T model), then disconnect the
connector (A). Connect a jumper wire from the battery positive terminal to the S terminal connector.

Fig. 3: Making Sure Shift Lever Is In N Or P Position

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Does the starter crank the engine?

YES - Go to step 11.

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

NO - Remove the starter, and repair or replace as necessary.

11. Check the following items in the order listed until you find the open circuit:

NOTE: After the problem in the circuit is found and repaired, go to step 14.

Check for an open or short in the YEL wire and connectors between the under-dash fuse/relay
l
box and the ignition switch.
l Check for an open or short in the RED wire, BLK/WHT wire and connectors between the
under-dash fuse/relay box and the starter S terminal connector.
l Check for an open or short in the ORN wire and connectors between the under-dash fuse/relay
box and the clutch interlock switch (M/T model).
l Check for an open or short in the ORN wire, BLU/WHT wire and connectors between the
under-dash fuse/relay box and the transmission range switch (A/T model).
l Check for poor ground at G401 (M/T model) or G101 (A/T model).

l Check for a faulty ignition switch.

l Check for a faulty clutch interlock switch (M/T model).

l Check for a faulty transmission range switch (A/T model).

l Check for a faulty starter cut relay.

12. Connect the alternator, regulator, battery & starter tester (OTC3131) to the battery.

NOTE: The probe is used for starter testing.

13. Do the STARTING TEST.

Does the display indicate the cranking voltage is greater than or equal to 8.7 V (M/T model)/8.5 V
(A/T model) and the current draw less than or equal to 230 A (M/T model)/350 A (A/T model)?

YES - Go to step 14.

NO - Replace the starter, or remove and disassemble it, and check for these problems:

lDrag in the starter armature

l Shorted armature winding

l Excessive drag in the engine

l Open circuit in starter armature commutator segments

l Excessively worn starter brushes

l Open circuit in the starter brushes

l Dirty or damaged helical splines or drive gear

l Faulty overrunning clutch

14. Remove the starter, and inspect its drive gear and the flywheel ring gear (M/T model) or the torque
converter ring gear (A/T model) for damage. Replace any damaged parts.
15. Select ECM/PCM reset (see ECM/PCM RESET ) to cancel ALL INJECTORS OFF on the HDS.

CLUTCH INTERLOCK SWITCH TEST

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2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

M/T

1. Disconnect the clutch interlock switch 2P connector (A).

Fig. 4: Identifying Clutch Interlock Switch 2P Connector

Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the clutch interlock switch (B).

3. Check for continuity between the terminals according to the table.
l If the continuity is not as specified, replace the clutch interlock switch.

l If OK, install the clutch interlock switch, and adjust the pedal height (see CLUTCH PEDAL,
CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH
ADJUSTMENT ).

Fig. 5: Checking Continuity Between Clutch Interlock Switch Table

Courtesy of AMERICAN HONDA MOTOR CO., INC.

CLUTCH INTERLOCK SWITCH REPLACEMENT

M/T

1. Disconnect the clutch interlock switch connector (A).

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2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Fig. 6: Identifying Clutch Interlock Switch Replacement

Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Loosen the locknut (B), then remove the clutch interlock switch (C).
3. Install the clutch interlock switch, and adjust the pedal height (see CLUTCH PEDAL, CLUTCH
PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT ).

STARTER SOLENOID TEST

M/T

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION ).

2. Remove the motor cable (A).

Fig. 7: Removing Motor Cable

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Check the hold-in coil for continuity between the S terminal and the armature housing (ground) (B).
There should be continuity.
l If there is continuity, go to step 4.

l If there is no continuity, replace the solenoid.

4. Check the pull-in coil for continuity between the S terminal and the M terminal. There should be
continuity.
l If there is continuity, the solenoid is OK.

l If there is no continuity, replace the solenoid.

5. Install the motor cable.

6. Install the starter (see INSTALLATION ).

STARTER PERFORMANCE TEST

M/T

1. Remove the starter (see Starter Removal and Installation).

2. Firmly clamp the starter in a vise.
3. Disconnect the starter motor wire from the M terminal.
4. Make a connections for this test using the thickest (gauge) wire possible (preferably the same gauge as
used on the vehicle).

NOTE: To avoid damaging the starter, never leave the battery connected for
more than 10 seconds.

Fig. 8: Connecting Battery To Starter

Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Connect the battery as shown in Fig. 8. Make sure you disconnect the starter motor wire from the
solenoid. If the starter pinion moves out, it is working properly.
6. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the
solenoid is working properly.

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Fig. 9: Disconnecting Battery From M Terminal

Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.

Fig. 10: Disconnecting Battery From Starter Body

Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Reconnect the wire to the M terminal.

9. Connect the starter to the battery as shown, and check that the motor turns and keeps rotating.

Fig. 11: Connecting Starter To Battery

Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is
working properly.

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 2008 Honda Civic DX
2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Specification Electric Current: 90 A or less

A/T

1. Remove the starter (see Starter Removal and Installation).

2. Firmly clamp the starter in a vise.
3. Make a connection for this test using the thickest (gauge) wire possible (preferably the same gauge as
used on the vehicle).

NOTE: To avoid damaging the starter, never leave the battery connected for
more than 10 seconds.

Fig. 12: Connecting Battery To Starter

Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Connect the battery as shown, and check for continuity between the B terminal and the starter body. If
there is continuity, it is working properly.
5. Disconnect the battery from the starter body, and check for continuity between the B terminal and the
starter body. If there is no continuity, it is working properly.

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2006-11 ENGINE Starting System (R18A1) - Civic (All Except Hybrid)

Fig. 13: Disconnecting Battery From Body

Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Connect the starter to the battery as shown, and confirm that the motor runs.

Fig. 14: Connecting Starter To Battery

Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is
working properly.

Specification Electric Current: 80 A or less

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