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Civic 01 - Coupe

Honda Civic Coupe

Contents

Introduction
A brief history
Body
Interior
Drivtrain
Chassis
Environment
Production and development
Technical specifications
Photographic resource

The following information is correct at time of going to press.

For more information: www.genpo.co.uk

Introduction

2 door Coupe is part of all-new global Civic range
Innovative 'short nose' design contributes to class-leading interior space
Flat floor for greater comfort
Refined, sporty styling
New 120 PS (88 kW) 1.7 SOHC and 125 PS (92 kW) 1.7 SOHC
VTEC-II engines
Quicker, better fuel economy, plus improved mid-range acceleration
All-new front and rear suspension provides agile handling
Best build quality yet

Blending strong dynamic performance, exciting new styling and an airy, open interior, Honda's latest Coupe is part of a powerful all-new Civic line-up that builds on the strengths of the company's most successful range of cars in Europe.

All the traditional Civic qualities of reliability, comfort, economical operation and a fun-to-drive nature are retained. But the Civic Coupe is completely re-engineered in every aspect for better dynamics, safety and build quality using, in true Honda fashion, innovative technologies, all packaged in a more distinctive, more overtly sporty design. And two highly advanced 1.7 litre engines bring an unrivalled blend of efficiency and sparkling performance to the coupe class.

Short nose concept plus flat floor

In creating a replacement for the Civic Coupe, the challenge was to provide a larger interior while retaining its compact dimensions and agile handling. The new Coupe is slightly shorter and taller than its predecessor. Yet despite the reduction in overall length, it offers substantially improved interior accommodation, reflecting the all-new, designed from the inside-out, concept of the car.

Clever packaging is the key. At the front there is a new compact toe control link MacPherson strut front suspension, a high-mounted steering gearbox and a compact engine bay. This in turn has enabled the front overhang to be reduced as part of a 'short nose' design concept which has the effect of freeing up more space for occupants and luggage.

At the rear a more compact double wishbone suspension combined with clever underfloor packaging - including a resin fuel tank moulded to fill the space available - has allowed a flat cabin floor without any central tunnel.

Class-leading interior space

The result is a remarkably spacious interior. The rear leg room, for example, has been increased by 8 mm to 833 mm. Together with the flat floor, the effect of which is to substantially improve rear seat comfort and allow unobstructed movement by passengers from one side to the other, plus a large glass area for good visibility, the Coupe provides a particularly light and airy interior.

Also, for added convenience, the front passenger seat has a 'walk-in' device with memory. This slides the seat fully forward when the seatback is tilted, for maximum rear seat access, and then returns it to the three-quarters position

Sporting intent

Honda was keen to ensure that the Coupe would have its own quite unique identity within the Civic range and its development and design was passed to a US-based team. The resulting short bonnet, long rear deck and cab-forward theme plus a strong sense of 'solid refinement' are also captured in the 4 door saloon. However, the more dynamic lines that result from steeply raked front and rear windscreens, low, tapering roof line and strong wedge profile, unambiguously state the Coupe's sporting intentions.

Innovative solutions in the quest for safety

A primary design objective was the accomplishment of outstanding levels of impact safety, together with pedestrian safety performance. The 'short nose' design was a true engineering challenge in this context, but the Civic's ingenious solution is to effectively split the impact energy along two parallel paths: the high stiffness front side members and the sub-frame beneath, providing impressive energy absorbing characteristics. Driver and front passenger SRS airbags and side airbags, front seatbelt pretensioners with load limiters and inertia reel seatbelts on all seats are standard equipment.

Elsewhere in the bodyshell there is extensive stiffening and use of high strength steel to provide an impressively strong structure. Overall body rigidity is also increased for better NVH and suspension refinement.

Luggage capacity up too

The Civic Coupe is more versatile than ever and boot capacity is increased by 46 litres to 441 litres (VDA). The rear seat back also splits 60:40 to allow lengthy items such as skis to be carried. Together with dimensions increased in all aspects - the width between the suspension pillars is up 348 mm to 1063 mm for example - the Civic Coupe offers outstanding load carrying capability for its class.

The relaxing, spacious cabin offers exceptional refinement. The extensive use of noise suppression materials, careful coordination of colours and textures, larger front seats and accommodation increased in all dimensions, combine with a more supple ride to make travel in the Civic Coupe a particularly pleasant experience.

Superb fit and finish

One of the most tangible indications of the new Civic Coupe's enhanced quality are the extremely close tolerances accomplished with the body panels, achieved in large part through new and advanced manufacturing techniques. In most cases the gaps have been halved, in some cases reduced almost to zero, greatly improving the fit and finish appearance. Attention to detail is apparent everywhere, including the interior where flush surfaces and reduced gaps for superior fit and finish, plus a higher grade of materials impart an air of high quality.

Refinement mirrors build quality and NVH characteristics have been targetted in all areas. Engine noise under acceleration, for example, is reduced by 3 dB(A) and the Civic Coupe benefits from a raft of measures including sophisticated engine mountings, high body rigidity and extensive use of melt sheeting, rubber mat insulators and urethane foam.

Choice of two brand-new 1.7 litre engines offering enhanced performance

Lively performance matching the Coupe's sporty looks is provided by a pair of advanced 1.7 litre engines. Both of these aluminium alloy based 16-valve units are lighter, more economical and engineered for greater torque than the engines they replace.

The 1.7 litre SOHC engine in the 1.7i LS model produces 120 PS (88 kW) at 6200 rpm compared to 105 PS (77 kW) at 6,200 rpm for the 1.6 SOHC of its predecessor. At the same time torque is boosted from 139 Nm at 4,600 rpm to 152 Nm at 4,500 rpm for even greater driving flexibility.

Similarly, peak torque of the 1.7 litre SOHC VTEC engine used in the 1.7i ES Coupe is 153 Nm at 4800 rpm, up from the 144 Nm at 5,400 rpm of the 1.7 litre SOHC VTEC engine in the previous Civic Coupe. Maximum output remains at 125 PS (92 kW), albeit at 6,300 rpm rather than 6,600 rpm. Together with an aerodynamically efficient body, this translates into punchier performance and fuel consumption better by some 10 per cent.

EU2005

Both engines substantially exceed the EU2000 emissions requirements and in some markets which benefit from additional tax breaks, the Civic Coupe complies with the stringent EU2005 levels which are not mandatory for a further 5 years.

Manual and automatic for all models

Both engines can be matched to either a 5-speed manual or 4-speed automatic transmission. The electronically controlled automatic, with extended torque converter lock-up for greater economy, provides more precise shifting and incorporates Grade Logic, the intelligent ratio selecting system. The manual transmission has been designed for shorter, more precise shifting.

Front and rear suspensions are all-new for an enhanced, supple ride and sportier handling, plus the packaging benefits already described. Toe control link MacPherson struts have been selected for the front suspension, while at the rear a new reactive link double wishbone set-up provides rear wheel toe-in under braking for greater stability. Ride comfort has been improved by reducing the spring rates of the front and rear compliance bushings while suspension rigidity generally is increased for better control and stability. Larger, 15 inch wheels for greater comfort are fitted with low rolling resistance tyres for better fuel economy. Alloys are standard on the 1.7i ES Coupe.

A high-mounted steering gearbox not only provides packaging benefits; the long tie-rods that result allow improved toe control. Indeed the toe characteristics of the toe control link MacPherson strut front suspension are more akin to those of a double wishbone design. A better balance between front and rear roll centres, an increased steering gear ratio and more linear steering response provide the Civic Coupe driver with an outstanding level of control and feel.

The extensive anti-theft equipment together with an easier to repair body structure are likely to result in lower insurance ratings.

The new Civic Coupe offers a high level of recyclability and as a further indication of Honda's progress in this area, most of the plastics used in the interior can be reprocessed and reused.

Equipment

The two Civic Coupe models available are related to engine type. The 1.7i LS features the 120 PS (88 kW) engine, the more comprehensively equipped 1.7i ES is powered by the 125 PS (92 kW) VTEC engine.

The standard equipment on the 1.7i LS (dependent on market) is as follows:

Driver and front passenger airbags
Side airbags
ABS with EBD
Brake Assist
Front disc brakes
Rear disc brakes
Front anti-roll bar
Rear anti-roll bar
Power rack and pinion steering with variable assist
Power windows
Electrically operated and heated door mirrors
Body-coloured door mirrors
Front seatbelt shoulder adjustment
Front seatbelt pre-tensioners
Adjustable 'halo' front headrests
Rear centre three-point seatbelt
ISOFIX child seat system
Rolling code immobiliser
Visible VIN
Security alarm (RHD only, optional on LHD)
Combined remote boot lid and fuel filler release
Front wiper coupled with washer
Driver's seat height adjustment
Height-adjustable steering column
Manual air conditioning (RHD only, optional on LHD)
60:40 split folding rear seat backs
Radio cassette and front and rear speakers
Radio aerial incorporated in rear windscreen
Central locking with remote operation
Driver and passenger magazine holder
Front cup holders
Amber switch illumination
Boot light
Dual vanity mirrors
Full wheel covers
Map light (RHD only)
Red safety reflector

Additionally, the 1.7i ES features:

Sunroof (dependent on market)
Headlight washers (dependent on market)
Automatic air conditioning
Security alarm
Map light
Alloy wheels
Body-coloured door handles
Welcome light

Optional equipment includes manual air conditioning and security alarm on the 1.7i LS (LHD only), 15 inch (1.7i LS) and 16 inch (1.7i ES) alloy wheels, rear under spoiler, boot spoiler, front and rear mudguards, front fog lights and side sill trim. Additionally, the ES model is offered with a leather option which includes leather upholstered seats, steering wheel, gear shift knob and heated seats.

The new global Civic range

The new Civic 2 door Coupe is part of a brand-new family of Civics being introduced to the market in a phased programme during the next 12 months. The Civic 4 door saloon will go on sale in selected European markets at the end of this year, and following the commencement of 5 door sales in early 2001, the new 3 door model will appear in European showrooms in autumn 2001.

The Civic is a truly global car: all variants share the same platform and the same basic specifications, although 2 door and 4 door models have a 60 mm shorter wheelbase. Both the 3 and 5 door models will be built at Honda's Swindon, UK plant. Honda's Japanese facilities will build 4 and 5 door models, while the US will supply the 4 door saloon and - uniquely - the 2 door Coupe.

New manufacturing system

The Civic is the first Honda to be launched simultaneously around the world and to ensure a consistent level of quality among the various manufacturing facilities, the company established the New Model Center in Tochigi Japan. From the earliest stages of development, manufacturing associates from Civic plants gathered there to provide critical input and the Center has used this information to formulate best build practices. The latest Civic is also the first global model to be built using Honda's New Manufacturing System which employs highly flexible welding robots and standardised assembly line layouts to reduce investment in new tooling.

Part of the development and manufacturing campaign has been a programme called 'Improving Quality 10 Times' or 'Q10' in which the goal has been to maximise quality gains in every aspect of the new Civic range - from the initial designs through to the final manufacturing process. This is most clearly illustrated by the excellent body fit and finish.

Product concept

From the very earliest development stages Honda has sought to infuse its all-new line-up of Civics with a range of abilities and a level of quality that would place them firmly at the forefront of the C-segment; the Civic Coupe is no exception.

That meant retaining its values of dependability and practicality while enhancing levels of comfort, handling and performance. In particular, the aim was to increase interior accommodation, in response to customer demand, without detriment to either its compact car agility or sporty performance. That this has been achieved, within external dimensions reduced in size, is testimony once again to Honda's use of innovative solutions to address given problems.

A primary goal, however, has been to make the Coupe more visually distinctive with clear sporting overtones. Typical customers of the previous Civic Coupe have tended to be of a higher average age than those for the coupe market as a whole, and more likely to be married and male. The buying decision has also been typically rational rather than emotional, and Honda is seeking to widen the appeal of its coupe model, predominantly aiming at the 25 to 40-year old, high income segment.

The marketplace

Honda's new Civic range in its various guises is particularly significant in that, following the launch of the current Accord range, it represents the second phase in a strategy aimed at boosting the company's presence in Europe's high-volume market sectors.

To put this into context, the C-segment was firmly in pole position within the European car market during 1999, with sales of 4.8 million units equivalent to a 32 per cent share of the total. Furthermore, the out-going Civic range in all its derivatives represented 42 per cent of the company's European sales in the same year (5 door 18 per cent; 3 door 13 per cent; Aero deck 6 per cent; 4 door 4 per cent; Coupe 1 per cent).

The new Civic Coupe enters a market that has remained fairly static over recent years and between 1993 and 1999 the sports/coupe sector accounted for 4 per cent of the total market. Honda expects to sell around 4000 Civic Coupes across Europe in its first year.

A brief history

The story of the phenomenally successful Civic range, justifiably ranked among the world's most successful car product lines, stretches over a period of almost 29 years culminating in today's launch of what is the seventh generation of Civic.

The debut of the Civic brand in July 1972 represented Honda's first 'mainstream' car, and signalled the company's arrival among the ranks of the world's leading car manufacturers. It has since played an important role in establishing the key attributes Honda vehicles have become known for: dependability, quality, reliability, and efficiency. The Civic has been Honda's best-selling vehicle around the world for more than 20 years.

The first Civic was a small, unpretentious, front-wheel drive hatchback and one of the first Japanese cars regarded as competitive against European contenders. Power was provided by a series of transverse four cylinder engines ranging from a 54 bhp 1169 cc unit to a 75 bhp 1488 cc unit.

Successive generations underwent progressive enlargement and benefited from enhanced specification and by the mid-1980s the Civic was quickly gaining a reputation for outstanding build quality. In the US the Civic's environmental credentials were established when the CVCC-engined model became the first vehicle, in 1975, to meet the Clean Air Act without the need for a catalytic converter, something most manufacturers said couldn't be accomplished.

Bigger and better engines eventually led in 1987 to the fourth generation Civic which boasted of four-valves-per-cylinder across the range plus the introduction of VTEC technology, bringing sophisticated engineering to the compact class; body variants included the tall estate-car style called the Shuttle and the CRX sports coupe.

By May 1995, the ten millionth - a fifth generation - Civic had emerged from the production line at Honda's Suzuka plant. The 1996 model year Civic became the first petrol-powered car to meet California's Low Emission Vehicle (LEV) standard. Significant from a European perspective, a new 5 door model became the first Civic to be built at the Swindon, UK plant.

The current sixth generation has grown to become one of the most comprehensive on the market with a choice of 2 door coupe, 3 door and 5 door models, 4 door saloon and 5 door Aero deck being produced from 3 different countries, Japan (3 door and 4 door), USA (2 door) and the UK (5 door and Aero deck).

Body

Shorter and taller overall
Same wheelbase retained
Short nose is key design element
Fresh, distinctive styling with sense of solidity
'Smart Linked' body structure achieves outstanding crash performance
Pedestrian safety a major consideration
Highly rigid body boosts NVH, handling and safety
57 per cent of bodyshell by weight is high-tensile steel
Bodyshell 12 per cent lighter
Extensive noise suppression measures
Body fit and finish improved still further
High level of anti-theft equipment

In the Civic Coupe Honda has met its primary objectives of enhanced safety, even tighter fit and finish, and reduced NVH in a design that is both attractive and distinctive while offering outstanding interior space.

Sleek, sporty look

Although familiar design cues recur throughout the Civic range, each body style has its own distinct personality and this is particularly true of the Coupe.

While Coupe and 4 door saloon share the same refined solidity and a similar frontal treatment - with the new Civic's signature short nose and steeply raked windscreen for a monoform look - from the A-pillar back each is unique. Indeed, only 22 per cent of sheet metal body panels are common and to achieve this separate identity, the two models were the responsibility of two distinct design teams. The saloon was designed by a team based in Japan, the Coupe by one based in the US.

A 40 mm lower roofline, together with a more sharply tapered (28.8 degrees) windscreen and C-pillar give the Coupe a sleeker profile and a more aggressive, wedge style. At the front the saloon's two bar grille with chrome trim along its top edge is replaced by a single horizontal bar and body-coloured trim; bright, jewel-like headlamps, featuring free form and multi-reflector technology are similar to those of the 4 door.

At the rear the bumper has an increased radius for a more dynamic feel and the tail lights are positioned lower; in side profile they feature their own pronounced wedge shape to enhance the Coupe's sporty image. Their unique signature when lit at night differentiates the Coupe from every other vehicle on the road.

An overall dynamic quality is provided by the continuation of the front wing profile back along the car in the form of a shoulder. This strong character line, passing through the door handles and flowing all the way to the taillights, imparts a solid, upmarket appearance. A second, more subtle crease at hip point level runs parallel to it and between the wheelarches. A black B-pillar creates a cohesive look to the side profile.

	New Civic Coupe	Previous Civic Coupe
Overall length	4438 mm	4450 mm
Wheelbase	2620 mm	2620 mm
Height	1399 mm	1375 mm
Width	1695 mm	1695 mm
Front track	1470 mm	1478 mm
Rear track	1470 mm	1488 mm

Behind the Short Nose

The new Civic Coupe is 12 mm shorter and 24 mm taller than its predecessor. Significantly, the wheelbase remains the same at 2620 mm, and the reduction in overall length comes from a smaller front overhang - indeed this dimension is substantially reduced, since the rear overhang is increased 40 mm for greater luggage capacity. It is this aspect of the front wheels being 'pushed' forwards, together with what Honda calls its 'short nose' concept that have a major bearing on interior accommodation.

Visually, the short nose - 65 mm less than its predecessor and with the base of the windscreen raked closer to the front wheels - is a key styling element; it is also an eminently practical feature since it frees up more space that can be devoted to occupants and luggage. The design has been made possible by the compact nature of the front suspension and the adoption of a high mounted steering gearbox, which in turn have allowed the repositioning of the engine within the engine bay for better space utilisation. Despite the reduced nose dimensions, the Civic Coupe offers outstanding crash safety characteristics.

Extensive use has been made of computer simulations for more efficient and cost-effective development of the body. As well as reducing development time, these techniques have allowed the engineers to minimise weight and determine the optimum materials while improving the overall design. One of the benefits to emerge from this process is a significant improvement in body rigidity. Torsional rigidity has been increased by 60 per cent, while bending stiffness is up by 78 per cent, which not only offers improved impact resistance, but also aids handling and ride by ensuring that the suspension mounting points always remain in correct alignment, and reduces interior noise levels by limiting body-panel resonance.

The Civic Coupe bodyshell is 8.5 per cent more aerodynamically efficient. The designers used a computer-generated 'virtual wind tunnel' to predict wind flow around the car and every aspect of the body was studied to reduce drag and minimise wind noise. This included developing the general shape of the body, refining the front spoiler, adding a rear suspension cover, even refining the shape of the rearview mirrors.

Ingenious underfloor packaging

One of the notable features of the Civic Coupe is its flat rear floor which provides a more comfortable environment for rear seat passengers. This has been achieved by clever underfloor packaging whereby the compact reactive link double wishbone rear suspension (see Chassis section) together with the adoption of a new plastic petrol tank allows the exhaust pre-chamber to be repositioned.

The 50 litre lightweight tank uses four different types of resin in six layers, and the fact that it can be moulded in an infinite variety of shapes, means that it can make the most effective use of the space available. By locating two silencers towards the rear of the car - rather than siting one pre-chamber midway along the exhaust - the floor can remain flat and in an ingenious piece of packaging, the smaller, high efficiency exhaust pre-chamber is placed between the tank and the suspension. This positioning has also improved rear ground clearance by 24 mm in the fully laden state. The larger final chamber is tucked behind the rear valance

Crash safety

The new Civic Coupe features an impact-resistant passenger cell, precisely calculated deformation zones, a number of innovative items designed to minimise pedestrian injury, and a complete all-round safety package for occupants. In turn, passive safety features are complemented by the advanced active safety features of the Civic design: safe, predictable handling, powerful braking with ABS and electronic brake force distribution, and precision steering.

Smart-Linked body

Behind the Civic Coupe's impressive crash performance is what Honda calls its 'Smart Linked' body structure technology. This refers to the way in which the size and cross-section of crossmembers and the way in which they link to the frame rails and side-sills has been optimised to achieve major increases in bodyshell stiffness; the effectiveness of each individual joint is amplified in this way.

The safety levels achieved are all the more impressive given two particular design features of the new Civic Coupe: first the short nose, and secondly the lack of a central tunnel in the rear floor, both of which have provided a greater challenge in managing impact energy and the need for innovative solutions.

Controlled G-forces

Employing Honda's progressive deformation technology has allowed the controlled collapse of the front side frame on impact, and more effective management of the G-forces exerted on occupants. Unlike conventional front end structures, the Civic Coupe's has two parallel paths along which frontal crash energy is absorbed: the front side frame and, beneath them and working in concert, the sub-frame. Energy is then channelled into the floor rails and the centre frame to efficiently disperse energy. Compared with the previous Coupe, the initial G forces are configured so that more of the energy is absorbed during the early stages of the impact cycle, which means that peak force can be more effectively managed to minimise any injury to occupants.

Body reinforcement

The Coupe includes several carefully designed components to reinforce the unique body structure of a coupe and deliver the ride and handling characteristics expected of it. Furthermore, to provide a high degree of strength without any associated weight penalty, 57 per cent of the bodyshell by weight is made from high-strength steel. Bodyshell weight is actually reduced by 12 per cent.

Notable features include:

a high-strength steel, mid-floor crossmember and floor gussets that are
attached with oversized, high-tension bolts
high strength steel for the front seat brackets
high-strength steel for side sill and side sill reinforcement
high-strength steel for the front floor crossmember
lower and upper A-pillar stiffeners
one-piece B-pillar stiffener
instrument panel beam
rear bulkhead stiffener
rear damper stiffener
side rail stiffener
laser welded rear inner panel and door panels reduce weight while increasing strength
high-strength front and rear bumper beams

Of particular significance, and unique to the Coupe, is a gusset that runs across the floor from one side to the other and passes through the B-pillars. This design helps to transfer side impact energy directly to the floor structure and body intrusion is reduced by more than 20 per cent as a result. It also has the added benefit of providing increased rear passenger foot room.

In terms of rear impact protection, the new suspension design has allowed for a straighter frame, and together with a more rigid connection between the side sill and rear side frame, impact absorption characteristics have been considerably enhanced.

Comprehensive safety equipment

As part of the comprehensive safety package, as well as both driver and front passenger airbags, the Civic Coupe is also fitted with side airbags for even greater protection in the event of an accident.

Front seatbelts feature pre-tensioners with load limiters, and all three rear seats feature three-point inertia-reel seatbelts. Front seatbelt upper anchors are height adjustable.

In addition, the interior trim incorporates a number of small detail safety items designed to reduce the risk of occupant injury in the event of an accident, including roof rail and window pillar trim with an impact absorbing structure for controlled deformation.

In the event of the car turning over in an accident, a special fuel system shut-off valve is activated to prevent spillage.

Targetting pedestrian safety

A key component of Honda's extensive research into pedestrian safety through accident avoidance and injury reduction has been the development of a safety research prototype vehicle, the ASV3, within the ASV (Active Safety Vehicle) project under the guidance of the Japanese Ministry of Transportation. The use of increasingly sophisticated pedestrian dummies, extensive road accident analysis and a computer-assisted accident simulation programme are providing invaluable data towards identifying and minimising the potential for injuries.

Specific items on the Civic aimed at minimising pedestrian injury include:

an unobstructed area beneath the bonnet which allows it to deform on impact
bonnet hinges that compress under impact
collapsible wiper pivot designed to break under impact

As part of the objective of driving down insurance and repair costs, Honda engineers focused their attention on reducing the damage that occurs in low-speed, under 5 mph accidents, which can result in very high repair costs. As a result, the new Civic Coupe is designed to minimise headlight and tailgate damage in this type of accident.

NVH performance

For the new Civic Coupe, Honda has placed considerable emphasis on securing the kind of levels of refinement more normally associated with larger cars. NVH performance is considerably improved by increased body rigidity, more extensive application of sound absorbing material, a reduction in idling vibration, low road tyre noise and comprehensive sealing of holes in the body structure.

Among the numerous measures adopted to prevent external noise from intruding into the cabin are:

urethane foam inside lower front pillar
foam block in lower B-pillar
foam block above rear quarter window
plastic sheeting over large holes in structure
sound absorbing roof lining with felt.
boot mat and side lining backing felt
floor carpet with high performance PET felt backing - 15 mm thick with a weight of 1.8 kg/m²
urethane foam fascia insulator
fascia undercover has Thinsulate layer (26 mm thick on the driver's side, 13 mm on the passenger's side)
bonnet insulator

Additionally there has been an increased application of anti-vibration melt sheet. This asphalt insulation material is literally 'melted' into place to ensure a precise fit:

foamed melt sheet on floor
melt sheet on floor aft of seats
melt sheet around spare wheel well
melt sheet around rear wheel housings

During development, the engineers discovered that the open area in front of the rear wheels was a source of noise. Special bags filled with a cotton/polyester fibre 'stuffing' material - like a big, loose pillow - are therefore inserted in the rear wheel well area to absorb rear wheel road and tyre noise.

Engine mount system

A sophisticated engine mounting system plays a large part in suppressing the transfer of noise and vibration to the interior space. The Civic Coupe has four mounts, two conventional attached to the cradle type sub-frame and two liquid-filled, attached to the side frame. Centrally mounted at the front of the engine bay is a lightweight extruded aluminium mount, while at the rear a second fixed bracket is made from resin which shears in the event of an impact, so limiting rearward movement of the engine and ensuring that it does not compromise the action of the crumple zone structure.

The two high-performance liquid-filled mounts attached to either side of the engine compartment - one for the transmission, the other for the engine - are slightly offset. This is because they are located along the axis of the engine's principal inertial moment (the axis about which the engine vibrates) and at these points, the least amplitude of engine vibration is transmitted from engine to frame, which significantly reduces engine-idle vibration. Together with the excellent absorption properties of the liquid-filled mounts, it means that engine noise and vibration are particularly well damped so adding to the general air of refinement within the Civic Coupe's cabin.

The engines themselves have received a number of enhancements to mitigate noise generation including a redesigned induction manifold for reduced induction noise, greater cylinder block rigidity and the addition of a timing belt automatic tensioner.

During acceleration, engine noise entering the cabin has been reduced by 3 dB(A) and road noise by 2.5 dB(A).

Hydro-formed sub-frame

The sub-frame itself - dubbed a shark's jaw by Honda engineers because of its unique shape - is made using a newly developed hydro-forming manufacturing technique. This makes it lighter and more rigid and is the first application of hydro-forming on a Honda vehicle.

The process involves a steel tube, one end of which is crimped, being placed in a die. Water, under extremely high pressure, is fed into the tube, forcing the tube to adopt the precise shape of the die. The resulting component is lighter than a comparable cast or stamped component.

Fit and finish

The excellent NVH characteristics attained by the Civic Coupe are mirrored in the level of exterior and interior build quality. Careful analysis of the build process, as part of the 'Q10' development and manufacturing campaign, resulted in the adoption of new manufacturing techniques (more details are provided within the Production section). These have brought increased body accuracy, evident in smaller panel gaps and in the improved door, boot and bonnet clearances, which are all the more significant given that Honda vehicles have long been synonymous with outstanding fit and finish.

As an example of what has been achieved, the new Civic Coupe features what is known as a '0' gap for the front and rear bumpers, or less than a single millimetre. This gives the bumpers a more integrated appearance.

Examples of other reductions are:

rear light housing to body gap reduced from 3 mm to 0.5-1 mm
headlight housing/bonnet from 6.5 to 3 mm
headlight housing/front bumper from 3 to 1 mm
headlight housing/front wing from 3 to 1 mm
front wing/bonnet from 4 to 3 mm
front wing/bumper from 3 to 0.5 mm
door/body gap from 5.0-5.5 to 3.5-4.0 mm along front and rear edges
fuel lid/body gap from 4 to 3 mm
boot lid/bumper from 8 to 6 mm

Similarly, there has been a comprehensive reduction in the corner radii of many body panels to enhance the sense of a neater, fully integrated design with an overall air of solidity.

Extensive anti-theft measures including standard rolling code immobiliser

A series of theft-deterrent measures have been incorporated into the Civic Coupe including a standard equipment rolling code immobiliser from which it is virtually impossible for thieves to clone the entry code.

The ignition key features a built-in transponder, which, when removed, immobilises the engine fuel injection and ignition so the engine cannot be started. When the key is reinserted and turned in the ignition, the transponder in the key transmits a code via an antenna built into the steering lock surround to the engine management computer. If the code, which changes each time the key is removed from the ignition lock, is confirmed by the engine ECU, the engine will start - but only then. The immobiliser multiplex control unit, engine ECU and ignition key/ignition barrel transponder are all linked via a bus communication.

Both models feature central locking with a remote keyless system that uses FM radio waves, rather than AM, for more effective operation.

Other security features provided as standard include:

immobiliser sticker on driver's window
lock knob flush with door interior
visible VIN
immobiliser
front and rear door handle protectors
door lock protectors
key rod protector on driver's door

According to grade, the following features are provided:

alarm
radio security
alloy wheel locks

Door lock and rod protectors are designed to deflect attacks where 'slim jim' type mechanisms are slid between the door and the side window glass to gain entry.

Where an alarm is fitted, it is activated upon the first locking action and deactivated as the doors are unlocked.

As a further anti-theft measure and also to reduce noise intrusion, the Civic Coupe's side windows feature a new sash construction that prevents the window from being pulled out, making entry from the outside more difficult.

Interior

Class-leading accommodation for both passengers and luggage
Totally flat floor
Interior unique to Coupe
High quality panel fit and finish
Comfort and ergonomics enhanced throughout
Improved rear seat access

Shorter than its predecessor it may be, yet thanks to the innovative packaging of the overall design, including the short nose concept, compact suspension and the underfloor arrangement of the rear exhaust and petrol tank, the Civic Coupe offers outstanding interior accommodation - particularly for rear seat passengers.

Rear legroom, for example, is up by 8 mm to 833 mm, while rear hip room is increased 25 mm to 1185 mm. The tandem distance, that is the distance between the front and rear hip points, and a good indicator of a car's spaciousness, is 768 mm compared to the previous Civic Coupe's 753 mm (+15 mm).

Easy entry and exit

Various measures, such as slide bar front seatbelts, make it easier to get in and out of the Civic Coupe. A new floor mounted bar is provided as the attachment point for the seatbelt, allowing the webbing to slide back automatically when the belt is unbuckled and ensuring unobstructed access to the rear.

In addition, the front passenger seat has a walk-in device with memory. When the seatback is tilted forward, the seat slides all the way to the front of its tracks, providing the largest possible opening for rear seat access. When the seatback is returned to its upright position, the seat slides back three-quarters of the way. The walk-in lever is located at the base of the front seat (on the back side) in easy reach of the rear seat passenger.

Flat floor enhances interior space

A totally flat floor, without the typical tunnel that runs the length of the interior, adds to the sense of spaciousness, particularly in terms of rear seat foot room. This has been made possible by the clever underfloor packaging (see Body section) with a resin petrol tank moulded to the most effective shape in terms of space utilisation together with a compact exhaust system that runs alongside it.

Flush surfaces, high quality materials

In selecting the interior materials, fixtures and fittings, Honda has aimed for a high level of refinement and quality. Careful attention has been paid to panel fit and finish, resulting in substantially reduced gaps and the application of flush panel joints and concealed fasteners wherever possible. The housings of the interior door handles are flush with the surrounding trim, for example, which although relatively minor detailing, can, of course, have a profound influence on a passenger's overall perception of the car. Other examples are:

flush joints between the window pillars and the roof lining
flush interior light
flush trim joints around the floor sills
flush sunroof
elimination of the gap between the A-pillar and the fascia
retracting grab handles
flush mounted rear coat hanger

The sunroof (optional for both versions) now features an aluminium sunshade and uses a much thinner motor, to give a higher level of rigidity and the liberation of over 25 mm of extra headroom.

The interior finish of the Coupe is substantially different to that of the Civic 4 door saloon. In keeping with the Coupe's sporty image, the interior fabrics feature larger patterns and use more colour while the door panels and rear side panels feature swooping curves that reflect the exterior styling of the car. Silver trim is applied to the window switch panel in the front door armrests and to the gearshift surround and instruments feature unique amber nighttime illumination.

For rear seat passengers the new Civic Coupe is an altogether more spacious proposition than its predecessor thanks to its flat floor design and greater width. The side panels are also deeply scalloped, providing excellent elbow room, while a waist-height grab handle attached directly to the body gives firm support during 'press-on' motoring and added assistance when entering and exiting the Coupe.

High quality materials for cabin trim and seat fabrics abound. The top of the dashboard has a distinctive textured finish. Front door panels either have a high quality fabric insert or leather when the leather upholstery option is selected on the 1.7i ES.

At the controls

Naturally, all aspects of driver ergonomics have undergone careful analysis to ensure as pleasurable a driving experience as possible. Steering inputs, pedal pressures, and the operation of controls generally have been analysed to ensure they function smoothly, progressively and above all predictably. The driver's view of the controls and instruments is direct and unobstructed, while their layout is logical.

The main display features four circular dials, with illuminated red needles, which are increased in diameter and feature larger white numbers on a silver background, adding to the sporty flavour. A large tachometer (on the left) and speedometer are flanked by a smaller temperature gauge (on the left) and a fuel gauge. The fuel gauge is a CPU-controlled unit which gives a linear response throughout the range of the tank and minimises needle vibrations. The lower portion of the speedo houses an LCD odometer/twin trip meter and (on ES grade) an outside temperature gauge reading from -30 to +45 C.

Compared to the previous Civic Coupe, there are a number of changes to the steering column stalks for easier operation. Instead of a rotary operation, the right hand wiper control now works in a vertical direction, while the left hand indicator stalk also incorporates the lighting controls with the outermost rotary element controlling parking and dipped beam, the inner rotary element the rear fog lamps. Moving the stalk forwards operates the main beam, moving it backwards operates the flick mainbeam. The power window switches in the door armrests, the remote control mirror switch on the fascia, the heater, audio, and hazard warning light switches are all amber illuminated. A combined internal fuel filler release and boot lid release are provided on the floor alongside the driver's seat.

The heater controls and audio system are mounted on the central fascia. There are two DIN standard apertures with a flush surface design allowing a wide range of alternative ICE units to be fitted. If unused, one of the two apertures provides an additional storage area.

The automatic transmission features a new 'cobra' type select lever, so-called because of its shape. This is significantly narrower and positioned 26 mm closer to the driver for greater ease of use. It is also fitted with a release button which is operated by a vertical push of the finger rather than a horizontal movement, reducing the risk of inadvertent shifting.

Sitting comfortably

Particular attention has been paid to minimising fatigue during long periods of driving. The totally new bucket front seats offer superb occupant support with cushion insert width increased by 47 mm and 16 mm higher side bolsters. Wider springs and a urethane foam that has been specially selected for its high damping properties minimise bounce and vibration.

Similarly, the seat back inserts are 21 mm wider and feature more pronounced side bolsters made up of several urethane foam types of varying hardness. Included in the Civic's standard specification are a height adjustable steering wheel and driver's seat height adjustment enabling the driving position to be fine-tuned to suit individual preferences. The front seats are fitted with a new sporty, open-type headrest which is also taller for greater support.

A significantly larger footrest - 90 mm longer and 35 mm wider - is provided for the driver's left foot for greater comfort on long drives.

The rear seats are highly sculptured to mirror those in the front and to provide excellent support.

Luggage swallowed with ease

At 441 litres, the new Civic Coupe boot offers an extra 46 litres of load space (VDA) matching exceptional interior accommodation with impressive load swallowing ability. A particularly compact rear suspension design (see Chassis section) means that the loading width between the suspension pillars is 1063 mm, an increase of 348 mm over the previous Civic.

Maximum boot width is increased by 32 mm to 1347 mm, and boot length is 86 mm greater at 1046 mm.

Furthermore, the size of the boot aperture between the loading lip and the base of the rear windscreen is up by 30 mm to 470 mm and together with a wide-opening boot lid plus a lower sill, the Civic Coupe offers outstanding load carrying capability for its class. In practical terms it will swallow two extra-large Samsonite suitcases, or four golfbags plus four small soft bags. Four luggage hooks are provided in the boot floor for greater load security.

Added versatility is provided by a 60/40 split folding rear seat back which allows lengthy items such as skis to be carried while still allowing four occupants to be seated in comfort.

ISOFIX mountings

The rear seats have ISOFIX standard child seat mounting points, allowing the seat to be fitted more safely and easily without any problems of slipping or tilting. Arms protruding from the base of the child seat lock into anchor bars located between the rear seat back and the seat cushion, firmly attaching the seat to the car body. The top of the child seat is held firmly in place by means of a strap which attaches to a tether anchor behind the seat.

A place for everything

The new Civic Coupe is provided with a number of useful storage areas around the cabin. First, the glove box capacity has been increased from 5.5 to 6 litres. There is a pocket below the radio that can accommodate three CDs. There's a convenient lower pocket in the centre console that is ideal for carrying sunglasses, and alongside the handbrake, a space that is handy for cigarettes, or a mobile phone, for example. The driver also has a flock-lined pocket for coins and other small items just beneath the air vent.

Ahead of the gearshift, in the centre console, are two cup holders, both of which will accommodate a large (500 ml) drinks bottle while still allowing access to the ashtray. A useful touch is that one of the holders has a series of ridges - 67, 73 and 89 mm in diameter - which ensure cups of different sizes are held securely in place.

Finally, the front doors contain large storage bins.

New improved speakers are lighter in weight

The new Civic Coupe provides an enhanced acoustic experience. The two front speakers and two rear speakers are of a new design; the 17 cm neodymium front speakers are housed in a resin frame are significantly lighter in weight resulting in a 1.32 kg saving per car, while the attachment to the door is much simplified. The use of neodymium magnets also improves the acoustics with better low and high pass characteristics and a reduction in high harmonic distortion.

Reception is provided by a new glass antenna incorporated within the rear windscreen. This has the obvious benefit of being less vulnerable to damage than a conventional aerial, especially if a car wash is being used, while it is able to provide maximum reception at all times.

Cool improvement

The air conditioning system has been increased in efficiency by 17 per cent. Condenser performance is up 23 per cent, while fan noise is reduced by a significant 2dB(A). The pollen filter, which is able to trap particulates down to 0.3 microns, has also been designed for very easy servicing; it simply requires the glovebox to be swung forward and away from its housing to gain access, a process which does not require any tools.

Dim the lights

With its convenient timed operation and dimming facility, the interior light is designed to provide a 'welcoming' introduction to Civic motoring. If the doors are unlocked with either the key or the keyless entry system, the interior light comes on at maximum intensity. It then remains on for 30 seconds after unlocking, for 3 minutes if the door is subsequently opened and for 6 seconds following closure of the door. However, if the doors are not shut properly the light will remain on for 3 minutes providing the engine is not turned on. Conversely, when the ignition key is removed after driving, or when the doors are unlocked from inside the car, the light remains on for 10 seconds. Again, opening the door prompts the light to stay on for 3 minutes, but if shut in the meantime, it will be extinguished after 6 seconds. In all cases there is a gradual reduction in illumination towards the end of the timed period before the light is finally switched off.

Drivetrain

Choice of 1.7 litre SOHC or 1.7 litre SOHC VTEC II
Extra torque boosts performance
Increased combustion efficiency, low friction and weight savings
Engines comply with EU2000 or EU2005 legislation (depending on market)
Choice of 5-speed manual or 4-speed automatic with Grade Logic Control

The Civic Coupe offers a choice of two aluminium alloy based four-cylinder petrol engines: a 120 PS (88 kW) 1.7 litre SOHC and a 125 PS (92 kW) 1.7 litre SOHC VTEC II. While output of the less powerful engine is boosted by 15 PS (11 kW) (compared to the previous 1.6i LS), the engineers have primarily sought improvements in mid-range torque, fuel consumption, refinement and reduced emissions. In markets where customers can benefit from tax breaks, improved catalyst equipment enables the engines to meet the strict EU2005 requirements.

A more flexible delivery

Better torque delivery has brought greater flexibility during everyday driving and helped improve economy. Compared to the equivalent 1.6 litre engines of the previous Civic Coupe, the 1.7 SOHC's peak torque rises from 139 Nm at 4,600 rpm to 152 Nm at 4,500 rpm, while that of the 1.7 SOHC VTEC II is boosted from 144 Nm at 5,400 rpm to 153 Nm at 4,800 rpm. Flatter torque curves also mean that both engines pull more strongly across the rev range, particularly between 2000 and 4000 rpm.

Maximum output of the 1.7 litre SOHC engine is 120 PS (88 kW) at 6,200 rpm up from 105 PS (77 kW) at 6,200 rpm. The 1.7 SOHC VTEC II unit produces the same 125 PS as its predecessor, but at 6,300 rpm rather than 6,600 rpm.

Fundamental to the improved engine characteristics are a number of measures aimed at boosting combustion performance. First, a new design of swirl intake port has optimised both vertical and horizontal vortices inside the cylinder ensuring excellent fuel distribution and thorough mixing for effective, stable and clean combustion. By ensuring more complete burning of the air-fuel mixture, a higher compression ratio has been made possible.

New fuel injector design

Small, 'four-port' fuel injectors are used in the new engines. Featuring four orifices, rather than the usual single nozzle, these are one third shorter than the conventional pintle-type design. They offer more efficient fuel atomisation for improved combustion, while the problem of fuel mist clinging to the port walls is also reduced. The result is a significant reduction - as much as 14 per cent - in the amount of unburned hydrocarbons passing into the exhaust gases. In addition, all engines are equipped with "knock" sensors.

Boosted torque

Torque characteristics have been further improved by reducing the length of the conduit between the air intake and the intake manifold chamber by 84 per cent. This has realised optimum resonance characteristics and torque at 4000 rpm is increased by 4 per cent.

EGR

Exhaust gas recirculation - introducing a proportion of the exhaust gases back into the fuel-air mixture - is an additional feature of the new engines. Its effect is to lower combustion temperatures which has the effect of reducing the levels of oxides of nitrogen for a cleaner exhaust.

The VTEC approach to economy

At the heart of the 1.7i ES Coupe's engine is Honda's renowned Variable Valve Timing and Lift Electronic Control (VTEC-II) system which so successfully provides volumetric efficiency at all engine speeds to achieve good low to mid-range torque and vivid top-end output, together with outstanding fuel economy.

Friction

Any means of reducing energy lost through friction is of vital importance in the quest for low fuel consumption and the Civic Coupe's engines employ some of the innovative technology seen in recently launched models such as the Honda S2000 and Insight. The piston skirts, for example, are shot-peened with small ceramic balls to give a special 'micro-dimple' surface which improves the retention of the oil film between the piston and the cylinder, reducing overall friction by approximately 2 per cent. The small end bearing width is reduced from 23 to 20 mm, and finally the VTEC engine features roller type rocker arms first seen in the Honda S2000 and Insight, rather than plain metal bearings, to provide a further 5 per cent reduction in friction losses.

The pistons are not completely round and have a new asymmetrical oval design. This maintains a tighter tolerance on the exhaust side so they seal better, reduce engine noise and friction.

Emissions

Both engines significantly better the EU2000 emissions requirements. Furthermore, for those countries where customers can benefit from tax reductions, a number of modifications have been introduced which mean that the Civic Coupe complies with the EU2005 requirements.

A crucial element in meeting these tough emissions levels is to bring the catalytic converter up to its effective operating temperature as quickly as possible. This is achieved by retarding the ignition timing after engine start to help promote rapid warming, while the exhaust system is of the low heat mass type for the same purpose. The catalytic converter is of the close-coupled type which means it is located as close as possible to the exhaust manifold, thus increasing efficiency after a cold start.

Fast, effective performance is also provided by increasing the number of cells integrated into the catalyst substrate to 900 per square inch, which gives three times the surface area. EGR helps to reduce oxides of nitrogen and finally, the small fuel four-port injectors deliver more efficient atomisation leading to a reduction in HC emissions.

Returnless fuel supply

Up to one third of all vehicle emissions occur while the vehicle is parked. The new Civic Coupe is therefore equipped with a returnless fuel supply system that effectively seals the tank to reduce vapour loss.

Weight down by 10 per cent

Engine weight has been reduced by around 13 kg - or 10 per cent - through both material and construction changes. These include:

plastic intake manifold saving 1.9 kg
fabricated exhaust manifold 1.6 kg
aluminium engine side mount 0.5 kg
plastic fan shroud 0.5 kg
aluminium ECU casing 0.2 kg
4-weight light crank 0.4 kg
exhaust-pipe-integrated catalytic converter 2.2 kg
PHC ignition system 1.0 kg
compact intake resonator chamber 1.3 kg.

Reduced dimensions

The engines are now more compact from front to rear, reduced by 42.5 mm from 617 to 574.5 mm. The better packaging results from the relocation of various ancillaries and the adoption of a more compact air intake system. Typically, the bulk of the air intake system is located on the car body rather than the engine, with the air-cleaner case assembly usually fixed to the inner wing area beneath the bonnet. With this new generation of engines, the air cleaner has been positioned over the intake manifold and the resonator chamber over the transmission.

Packaging also benefits from a new PHC ignition system which locates a small high-performing coil above each spark plug, improving combustion efficiency and allowing reduced external engine dimensions.

Apart from freeing up greater space for occupants without increasing vehicle length, the more compact nature of the engine means there is more space available for the impact absorbing structures of the bodyshell to work effectively.

Noise reduction

Engine noise during acceleration and while at idle has been reduced by 6dB (A). Among the noise-reduction measures are:

an automatic tensioner for the timing belt assembly
a narrower timing belt with reprofiled teeth
a new equal-length intake manifold which has eliminated the air induction noise typical of systems with different length intake runners
rigidity of the cylinder block walls increased to minimise piston knocking noise at idle
larger and stronger engine mounting brackets for less vibration during acceleration
crankshaft web thickness increased by 1.5 mm for increased crankshaft rigidity which translates into reduced noise and vibration during acceleration
connecting rod bearings with a textured surface to better hold oil for consistent lubrication and a smoother running engine

Transmissions

Both the 1.7i LS and 1.7i ES models can be specified with either a 5-speed manual transmission or a 4-speed automatic with Grade Logic Control. Both are new designs.

Manual transmission

The manual transmission benefits from a number of detail enhancements which have reduced the effort required to change gear and at the same time improved feel. In particular, the detent shape of the shift fork has been refined for a light and precise action, while synchromesh capacity on first gear is boosted 20 per cent by using a carbon-impregnated synchroniser and on second gear by a double cone mechanism. Other refinements include the use of smaller, high capacity bearings and synchroniser sleeves with a shorter stroke for a lighter, more compact gearbox casing. Reverse gear is precision forged.

Beneficial from an environmental and fuel efficiency standpoint are a reduced oil capacity and, during the production process, a reduction in gear machining.

Flexible flywheel

An added touch of refinement is provided in manual models by a 'flexible flywheel'; this consists of a flexible plate connecting the flywheel and the crankshaft centre plate and able to absorb the naturally-occurring crankshaft vibrations which would otherwise transfer to the flywheel itself. Even greater in-car refinement is the result.

Automatic transmission with extended lock-up

The compact automatic transmission is a sophisticated, four-speed, electronic constant mesh unit. It features a torque converter lock-up which is operational over a greatly extended speed range, benefitting fuel economy by around 3 per cent.

Grade Logic Control

The new automatic transmission incorporates Grade Logic Control, an intelligent system that has already appeared in several other Honda models and which, unlike conventional automatics, offers seamless progress over variable road conditions, particularly hilly routes where it can provide the driver with the same degree of control as a manual transmission.

Its advantage lies in its ability to determine the actual driving situation by measuring throttle position, road speed, rates of deceleration and acceleration and brake pedal application and then, based on a series of stored shift maps, to select the appropriate shift points for second, third and fourth gears. Thus, when the Civic Coupe is being driven uphill, Grade Logic will sense a large throttle opening without any speed increase, and from this deduces that the vehicle is going uphill and how steep the grade is. It then chooses a shift map that will downshift and hold third or even second gear.

However, if it receives a closed throttle signal and a brake pedal activation signal, the system determines that the car is being driven downhill. It then selects a shift map that will downshift and hold third or second gear to make use of engine braking. Similarly Grade Logic can use a rapid deceleration signal and a closed throttle to determine that the car is entering a tight bend; it then chooses a shift map that downshifts early for more responsive acceleration. The same set of inputs occurs in the abrupt braking followed by quick acceleration that often accompanies stop-and-go town driving, thus promoting smoother driving.

Lock-up linear solenoid

Other features of the automatic transmission include a long torsion damper spring around the outer circumference of the lock-up clutch disc which provides effective absorption of vibration and a reduction in surging; a dedicated lock-up linear solenoid to control the hydraulic pressure to the gear clutch packs, providing more progressive clutch engagement and faster, smoother shifting; and an electronic control that is programmed to minimise 'shift shock' during full or part throttle upshifts and downshifts.

Chassis

Compact Toe control link MacPherson strut front suspension aids engine packaging
High-mount steering gearbox contributes to excellent toe control characteristics
Compact reactive link double wishbone rear suspension contributes to flat floor cabin
High rigidity suspension components improve handling
High body rigidity permits supple ride
ABS and EBD braking also standard

Honda has long enjoyed a reputation for fine-handling cars thanks to extensive use of advanced suspension technology. In the new Civic Coupe, the target of the engineers was to enhance that reputation while at the same time contributing to the requirement for a more spacious cabin. In this they have succeeded and the result is substantially increased interior accommodation together with the kind of precision driving experience that Civic owners have come to expect and demand: a smoother, supple ride with reduced body roll, linear steering, and a high degree of stability during directional change. While the Coupe's suspension is essentially the same as for other Civic models, damper and bush settings are fine-tuned for a more sporty response.

Toe control link MacPherson strut front suspension

At the front, the choice was made to use a new toe control link MacPherson strut arrangement, together with a high-mounted steering box. The adoption of struts rather than a double wishbone design has allowed a more compact suspension: its dimensions are reduced by 56 mm longitudinally, while the engine bay width is increased by 80 mm compared to the previous Coupe.

High-mount steering gearbox

Together with a steering gearbox located 227 mm higher (which gives more space for the front sub-frame to deform in frontal impacts), it means the engine can be located further towards the rear of the engine bay, thus helping to achieve the 'short nose' design to free up more space for use within the cabin.

The position of the steering box means that the track rods are increased in length by 221 mm (or by 43 per cent) to provide improved toe control (the amount the tyres angle in towards or away from the body). The geometry is such that toe characteristics over the vertical travel of the wheel are more akin to those of a double wishbone arrangement and substantially improved in comparison to a conventional strut arrangement. The Civic Coupe's new front suspension moves from slight toe-out at full bump to slight toe-in at full rebound; whereas conventional struts move from substantial toe-out at full bump to almost neutral in the median position and back to substantial toe-out at full rebound. The result is far better tyre contact with the road.

Reactive link double wishbone

At the rear the aim was to minimise damper intrusion into the cabin, so maximising load space, without compromising handling or ride. A reactive link double wishbone design was selected, but one that is more compact than the previous Coupe's.

A significant feature is its toe-control arrangement which means that under braking, the rear wheels toe-in to provide exemplary stability. As the car is braked, the brake force is transmitted through the suspension structure which causes the rear mounted toe control arm located at 90 degrees to the force to flex backwards. The slight movement of the suspension structure to the rear that results in turn acts on the compliance bushes that locate the lower wishbone to the chassis. Their compliance in a diagonal direction pulls the trailing arm into a toe-in direction.

The design of the rear suspension is such that the spring, damper and lower wishbone are moved further outboard, thus requiring less space than before. It means the boot width between the suspension towers is increased by 348 mm to 1063 mm for better load swallowing capability.

The location of the lower wishbone also allows the exhaust pre-chamber to be slotted between it and the fuel tank, which in turn permits a flat floor.

More rigid suspension components

Suspension effectiveness is improved significantly by the torsionally stiff body together with the use of more rigid suspension components. It means any sudden loads do not move the suspension away from its ideal alignment and tyre contact is therefore increased for greater stability.

The front sub-frame and body together form an extremely stable unit that functions as an excellent platform for the front suspension, as well as yielding a high degree of isolation from vibration. The rigidity of the front suspension lower and upper arm bushings is up by 210 and 375 per cent respectively, while at the rear trailing arm rigidity is up 10 per cent and the wheel bearing is up 40 per cent. Tyre-to-ground contact at the front is more or less comparable to the double wishbone design of the previous Coupe, while at the rear it is increased by 31 per cent for greater stability, markedly improved handling and ride comfort.

Movement of the rear wheels on bump includes more rearward motion than on the previous Coupe, giving a more supple ride quality.

Improved front to rear balance

There is also now a better balance between the front and rear roll centres, to provide less pitch angle, and more stable and precise and linear handling characteristics during cornering. The suspension roll centre is 85.7 mm above ground level at the front and 156.7 mm at the rear.

Wheels and tyres

The new Civic Coupe has larger, 15 inch diameter wheels and tyres for improved comfort and handling. The 195/60 R15 tyres also offer reduced rolling resistance for better fuel economy. The 1.7i LS model is equipped with steel wheels with full trims, while the 1.7i ES model features alloy wheels.

Power steering

Through fine tuning, Honda has sought to improve steering response and feel. The steering ratio has been changed from 17.5:1 to 14.5:1 for a more nimble response and the rate of change is designed to be more linear, enabling the Civic Coupe to track smoothly through corners.

In comparison to the number of revolutions of a conventional power steering pump, a linear injection volume is achieved with a relief valve, which adjusts the necessary power assist through oil quantity control. Due to the variable type pump cam, unnecessary oil injections in the 900 rpm and higher range are eliminated, resulting in a 0.5 per cent improvement in fuel economy.

On the road the system set-up translates into a crisp, linear action offering excellent precision and weight at high speeds, and low effort at parking speeds.

Standard equipment ABS plus EBD

As well as four-sensor, three-channel ABS, the new Civic Coupe has Electronic Brake force Distribution (EBD). The latter is able to measure small front and rear wheel speed differences to ensure exactly the right amount of braking effort is applied to the rear wheels, via the ABS actuator, whatever load the car is carrying and taking into account the load transfer during deceleration. This allows the full potential of the rear brakes to be realised and both reduces the risk of premature rear brake lock-up when braking from high speeds and offers a more consistent pedal-feel.

The brake pedal action has been re-engineered to provide greater braking force over a shorter pedal stroke for a more precise and more linear action.

The new Civic also has a brake assist system. This comprises of a master power device which increases the master power braking output under emergency braking conditions.

Environment

Honda has made great strides in recent years in reducing the environmental impact of its products both during production and in subsequent use.

The new Civic Coupe continues that tradition and a particularly significant feature of the new model is that most of the plastic materials used within the interior are comprised of thermoplastic olefin (polypropylene) compounds which can easily be reprocessed into pellets and recycled.

Other key environmental aspects include compliance with EU2000 and EU2005 emissions legislation and the returnless fuel supply system (see Engine section); and a wiring harness which is lead-free and uses compact routing to reduce cable runs.

Production and development

Global coordination by New Model Centre
Digital Manufacturing Circle development process
Civic is first global model to be built using New Manufacturing System
Q10 quality programme
Advanced new manufacturing techniques for increased body accuracy

The new Civic in its various body styles is the first Honda to be launched simultaneously around the world. This was accomplished by combining the capabilities of Honda's autonomous business regions with global coordination through the New Model Center and New Manufacturing System.

A major challenge in planning this global Civic launch was ensuring a consistent level of quality around the world. To meet this challenge, Honda established the New Model Center in Tochigi, Japan. From the earliest stages of development, manufacturing associates from Civic plants gathered at the New Model Center to provide critical input on the Civic development.

Thousands of suggestions generated by the various plants on how to best build the new Civic to a higher quality standard were brought together into a single database at the New Model Center. Civic engineers were able to access this information during the development process and associates tested the results while assembling prototypes.

Through this process, the design team was able to create a vehicle that can be produced on a global basis with high quality, efficiency and at a lower investment. This is true at both the large, highly automated plants in Japan, the U.S. and Europe, and at smaller, less automated plants located in developing nations.

The new Civic is the first global model to be built using Honda's New Manufacturing System. The system employs highly flexible welding robots and standardised assembly line layouts to reduce investment in new tooling, while shortening the time needed for new model development and manufacturing ramp up. This flexible system will also allow Honda to adapt more quickly to changes in the marketplace with the production capability to add or change products in a short period of time, with minimal new investment.

Honda also applied a new development system called Digital Manufacturing Circle (DMC). This uses state of the art Information Technology systems to increase the speed and efficiency of the new model development process. The DMC system connects all the processes of Honda R&D, Honda Manufacturing and Honda suppliers by computer network, allowing them to share the same computer digitised drawings to develop new product designs through digital simulation. As a result, Honda is able to develop new vehicles in a shorter time using fewer costly prototype models and parts.

A new level of quality

"Improving Quality 10 Times" is the goal behind a development and manufacturing campaign codenamed "Q10". This philosophy is reflected in every aspect of the 2001 Civic from the initial+ designs through to the final manufacturing process. Some of the areas where the Q10 initiative is most evident on the new Civic are in the area of increased body accuracy making significant improvements in the fit and finish of panels and interior components.

Some of the manufacturing techniques that made these tighter tolerances possible included:

Advanced programmable robots this new equipment provides more precise welds, which translates into tighter tolerances. In addition, these robots can perform more functions, which 'shortens' the production line.
Honda engineers created a special 'servo gun' that allows these robots to do more precise spot welds. This design is easier to control and moves faster than comparable hydraulic guns, which are used on other assembly lines. In addition, the electric servo guns require less energy to operate.
With these new advanced welding robots, in most instances, the welding head remains stationary and the part is rotated. In the past with the hydraulic systems the part was stationary and the welding head moved, which is not as accurate.
Accuracy was also improved by converting the existing manufacturing process to use a specialised jig for more precise, automated installation of the hinges and door panels. In the past, a skilled associate undertook door panel installation by hand.

The use of high-tensile steel also creates added challenges in manufacturing, as it is considerably harder to form than typical sheet steel. This can prematurely wear dies (which can have a negative impact on quality and body clearances), and it is harder to weld and inspect. To overcome this challenge, Honda production engineers devised ways to create new durable dies and effectively check to ensure every vehicle is built to the same exacting tolerances.

HONDA CIVIC 2 door

Versions	1.7i LS *			1.7i ES *
ENGINE	1.7			1.7
	SOHC			SOHC VTEC II
Cylinders	4 in line
Bore x Stroke (mm)	75 x 94.4			75 x 94.4
Capacity (cc)	1668			1668
Compression ratio	9.5			9.9
Max power kW/PS @ rpm	88/120 6,200			92/125 6,300
Max torque Nm @ rpm	152 4,500			153 4,800
Fuel system	Honda PGM-FI electronic fuel injection
Fuel rating	Unleaded 95 Ron
ELECTRICAL
Battery	12 V 45 Ah
Alternator	12 V 70 Ah
TRANSMISSION
Front Wheel Drive
Gear Ratios
Manual 1st	3.461			3.461
2nd	1.869			1.869
3rd	1.241			1.241
4th	0.969			0.969
5th	0.805			0.805
Reverse	3.230			3.230
Final	4.411			4.411

Automatic - 1st	2.722			2.722
2nd	1.468			1.468
3rd	0.975			0.975
4th	0.673			0.711
Reverse	1.954			1.954
Final	4.357			4.357
SUSPENSION
Front Rear		Toe control link MacPherson strut, coil spring, gas pressurised shock absorber, 25.4 mm dia anti-roll bar Reactive link double wishbone, coil spring, gas pressurised shock absorber, 12 mm dia anti-roll bar
STEERING
Gear Type			Power assisted rack and pinion
Turns lock to lock			2.75
Turning circle (m)			11.6
* Dependent on market

Versions	1.7i LS *	1.7i ES *
BRAKES
Front	Ventilated disc 262 mm dia
Rear	Solid disc 260 mm dia
	Four-sensor, three-channel ABS, Electronic Brake Force Distribution (EBD) and brake assist
WHEELS AND TYRES
Wheels Tyres	15 x 6JJ (steel) 195/60 R15	15 x 6JJ (alloy) 195/60 R15
DIMENSIONS, WEIGHTS, CAPACITIES
Overall length (mm)	4438
Overall width (mm)	1695
Overall height (mm)	1399
Wheelbase (mm)	2620
Front track (mm)	1470
Rear track (mm)	1470
Ground clearance (mm)	155
Luggage space VDA (litre)	441
Kerb weight (kg) MT/AT	1121-1140/1147-1165	1130-1162/1155-1187
Max permitted weight (kg) MT/AT	1570/1595	1590/1615
Fuel tank (litres)	50
PERFORMANCE
Max speed (km/h) MT/AT	200/187	201/195
Acceleration (0-100km/h secs) MT/AT	9.7/11.1	9.6/11.1
Fuel consumption MT/AT l/100km (1999/100/EC)
Urban	9.3/10.1	9.0/9.9
Extra Urban	5.7/5.8	5.5/5.7
Combined	7.0/7.4	6.8/7.3
CO₂ emissions (g/km) MT/AT	168/176	161/173
* Dependent on market with passengers in vehicle