oil level HONDA CIVIC 1996 6.G Workshop Manual

Standards and ServiceLimits
Section '14Automatic Transmission (cont'd)
UO
MEASUREMENTSTANDARD {NEW}
Wire Dia.o.D.Free LongthNo. ol CoilsHegulator valve spring ARegulato. valve spring BStator reaction springModulator valve springTorque convener check valve springCooler relief valve springRelief valve spring2nd oritice control valve spring1-2 shift valve spring2-3 sh ift valve spring3 4 shift valve spring'l st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd acc!mulator spring B2nd accumulator spring CLock up shift valve springLock up timing valve springLock-up control valve spring3 4 ofifice control valve springServo control valve springCPC valve springCPB valve spring4th exhaust valve spring
Springs1.8 {0.071)1.8 {0.071)4.5 \O.117)1.4 (0.055)
1.0 10.039)1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.035)
2.1 (0.083)
2.3 (0.091)
2.610.102)2.4 (0.094)
2.8 (0.'110)
1.6 (0.063)
2.2 (0.087)
2.2 t0.041)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.7 (0.028)
1.0 (0.039)
0.6 (0.024)
0.9 {0.035)0.9 (0.035)
14.7 (0.584)
9.6 (0.381)
3s.4 (1.407)
9.4 (0.374)8.4 (0.334)
8.4 (0.334)
8.6 {0.342)6.6 (0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)16.0 (0.636)10.2lo.402l17.0 {0.676)29.0 (1.152)
17.5 (0.6951
9.0 (0.358)
31.0 (1.220)
14.5 {0.576)7.6 (0.302)
8.1 (0.319)
6.610.262)6.6 (0.262)
8.1 (0.322)
5.6 (0.2231
8.1 10.322)6.1 10.242)
87.8 (3.457)
44.0 i.732l'30.3 (1.193)
35.0 {1.378)33.8 (1.331)
33.8 (1.331)
37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57.0 (2.2441
51 .0 \2.244189.1 {3.508)51.6 (2.031)
87.0 (3.425)
39.011.535)89.3 (3.516)
20.7 (0.815)
35.1 11.382)68.012.671173.7 12.902)80.7 (3.177)38.0 {1.496)37.5 fi.476)52.1 (2.051)
12.2 (0.480)
47.2 {1.858}36.4 {1.433)
16.511.01.910.94.24.213.422.016.326.826.a16.213.814.22.915.66.12.413.932.045.814.124.620.4
18.319.5
CVTSection 14
3-14
MEASUREMENTSTANDARD INEWISERVICE LIMITTransmissionfluidCapacity f {US qt, lmp. qt)6.4 {6.8, 5.6) for overhaul3.9 (4.1, 3.4) for fluid change
Hydraulicpressure
1kgflcm,, psi)
Forward clutch pressure at 1,500 rpm in E position1.4 - 1.15 114.3 - 11.A,203 - 2531Reverse brake pressure at 1,500 rpm in E position1.4 - 1.75 (14.3 11.8,203 2531Dr;ve pulley pressure at 1,500 rpm in E posrtrono.2 -0.7 12.0 -7.1,28- 1011Driven pulley pressure at 1,500 rpm in N positionr.5 - 2.3 115.3 - 23.5, 218 - 334)Lubrication pressure at 3,000 rpm in E posrtronAbove 0.212,30)Stall speed fpm (Check with vehicle on level ground)
E position
E, E, El positions2,5003,0002,350 - 2,6502,800 - 3, r00ClutchClutch initial clearance Forward clutchStart clutchReverse brakeClutch return spring free length Forward clutchStart clutchReverse brakeClutch disc thickness Forward clutchStart clutchReverse brakeClutch plate thickness Forward clutchSta rt clutchReverse brake
0.6 - 0.8 (0.024 - 0.031)0.5 - 0.7 (0.020 0.028)0.45 - 0.75 (0.018 - 0.030)30.5 {1.201)40.9 (1.610)
29.4 (1.157)
1.88 - 2.00 (0.074- 0.079)1.88 2.00 (0.074 - 0.079)1.94 - 2.06 (0.076 - 0.081)1.95 - 2.05 (0.077 -0.081)
2.25 2.35 (0.089 - 0.093)1.90 - 2.00 (0.075 0.079)
,*x.ar}38.9 (1.531)
27.411.019l'Until grooves worn out
Until grooves worn outDiscolorationDiscolorationDiscoloration
L.

Engine Oil
Inspection
1.Park the vehicle on level ground, and turn off theengine. Allow the oil a few minutes to drain backinto the oil pan so the dipstick will show the actuallevel.
Make certain that the oil level indicated on the dip_stick is between the upper and lower marks.
lf the level has dropped close to the lower mark.add oil until it reaches the upper mark.
CAUTION: lmert thc dipstick car€fully to avoid b€nd_ing it.
Bl6A2 angin.:
,,7.fp--)*,".
rowrn-u l
D16Y5, D16Y7, Dt6y8 ongines:
8-6
Replacement
CAUTION: Removo the drain boli carefully while lhoengine is hot; the hot oil may causo scalding.
:1. Warm up the engine.
2. Drain the engine oil.
81642, D16Y7 engin€s:
{rl N.m (4.5 kgf.m,33 tbt ft}Do not overtighten.
D16Y5, Dl6Y8 6ngin93:
WASHER
DRAIN BOLT39 N.m 14.0 kgfm, 29 tbf,f0uo not overtighten.
DRAIN BOLT

Oil Pressure
Use this procedure to tighten the filter if eight num-
bers (1 to 8) are printed on the surface of the filter.
1) Make a mark on the oil filter base under the num-
ber that shows at the bottom of the filter when
the rubber seal is seated.
2l Tighten the filter by turning it clockwise seven
numbers from the marked point. For example, if a
mark is made under the number 2 when the rub
ber seal is seated, the filter should be tightened
until the number 1 comes up to the marked point'
7/8 turn
Number when rubDer
seal is seated
Number after tightening.
CAUTION: Using any procedure other than those
shown could rosult in serious engins damage due
to oil leakage
5. After installation. fill the engine with oil up to the spec-
ified level, run the engine for more than three minutes,
then check for oil leakage
MARK
Number when rubber
seal is seated578
Number after tightening8151
Testing
lf the oil pressure warning Iight stays on with the engine
running, check the engine oil level. It the oil level is cor-
rect:
1. Connect a tachometer'
2. Remove the engine oil pressure switch, and install an
oal pressure gauge.
ENGINE OtL PRESSURE SWITCH
MOUNTING HOLE
ADAPTER(1/8\28. BSPTI
{CommerciallY availablei
Start the engine. Shut it off immediately if the gauge
registers no oil pr€ssure. Repair the problem before
continuing.
Allow the engine to reach operating temperature (tan
comes on at least tlivice). The pressure should be;
Engine Oil Temperature: 176"F (80"C1
Engine Oil Pressulo:
At ldle: 69 kPa (0.7 kgf/Gm'. 10 Psi)
minimum
At 3.000 rpm: 3/Ut kPa (3.5 kgt/cm', 50 psi)
minimum
. lf the oil Dressure is within specifications, replace
the oil pressure switch and recheck.
. lf the oil pressure is NOT within specifications,
inspect the oil pump (see page 8-10).
OIL PRESSURE GAUGE(Commerciallv available)
8-9

MaintenanceBack-up Light Switch
Transmission Oil
NOTE: Check the transmission oil with the engine OFF
and the vehicle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUG/14 N.m (4.5 kgl.m,33 lbl.ft)Proper Level
4.
WASHERReplace.
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out. then rein-
stall the oil filler plug with a new washer.
lf the transmission oil is dirty, remove the drain plug
and drain the oil.
Reinstall the drain plug with a new washer, and refill
the transmission with the recommended oil to the
proper lever.
NOTE: The drain plug washer should be replaced at
every oil change.
Reinstall the oil filler plug with a new washer.
OilCapacity
1.8 f (1.9 US qt. 1.6 lmp qtl at oil change
1.9 { (2.0 US $, 1.7 lmp qt) at overhaul
Always use Genuine Honda Manual Transmission
Fluid {MTF). Using motor oil can cause stiffer shift-
ing because it does not contain the proper addi-
t|ves.
\
\
Replacement
NOTE: To test the back-up light switch, see section 23
1. Disconnect the connector, then remove the back-up
light swirch connector from the connector clamp.
2. Remove the back-up light switch.
25 N.m (2.5 kgf'm, 18lbf'ltl
Install the new washer and back-up light switch
Connect the back-up light switch connector.
ASHER
13-3

MaintenanceBack-up Light Switch
\
Transmission Oil
NOTE: Check the oil with the engine OFF. and the vehi-
cle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUGia4 N.m {{.5 kgf'm,Proper Level33 tbtfrl
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out, then rein-
stall the oil filler plug.
lf the transmission oil is dirty, remove the drain plug
and drain the oil.
Reinstall the drain plug with a new washer. and refill
the transmission oil to the proper level.
NOTE: The drain plug washer should be replaced at
every oil change.
Reinstallthe oilfiller plug with a new washer.
Oil Capacity
2.2 f {2.3 US. qt, 1.9 lmp. qtl at oil change.
2.3 f {2./f US. qt. 2.0 lmp. qt} at overhaul.
Always use Genuine Honda Manual Transmission
Fluid (MTF). Using motor oil can cause stiffer shift-
ing because it does not contain the proper addi-
tives.
OIL FILLER PLUGila N.m {4.5 kgf.m, 33 lbt'ftl
Replace.
\1,
Replacement
NOTE: To check the back-up light switch, see section 23.
1. Disconnect the connector, then remove the back-up
light switch connector from the connector clamp.
2. Remove the back-up lighr switch.
AACK.UP25 N.m 12.5 kgf.m, 18 lbf'tt)Replace.
lnstall the new washer and the back-up light switch.
Check the transmission oil level.4.

Automatic Transmission
Special Tools ......... .....'."".'-.-.' 14'2
Description .,....................-...... 14-3
power Flow ......,................. 14"6
Elestronic Control System .... . ................'..'.'.. 14-13
Hvdraulic Control .....'......" 1'l-19
Hydraulic F|ow...... .'.'.".'....11-21
Lock-up System '............ ... t/t'33
Electrical System
Component Locations....,.............'......'.............'.,. 14'39
PCM Circuit Diagram
lA/T Control Syst€m: '96 - 98 Models) .........'.. 1/t-40
PCM Tarminal Volt8ge/Measuring Condhions
{'96 - 98 ModeblA/T Control System ............
PCM Circuit Disgram(A/T Conlrol System: '99 - 00 Modsls) '..........' 14-44
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)A/T Control System ...
Troubleshooting Proceduros ....
Symptom-to-ComPonent Chari
Efectricaf SFiem - '96 - 98 Models '..-.-..."'.'..11-52
Eloqtrical System -'99 - 00 Modols ... .........". 1+54
EleclricatTroubl$hooting ('96 - 98 Models)
Valve Body
Repair .................... ........'.... 14-139
Valve
Assembly
ATF Pump
1,1-1i10
Inspection ...........'.......... 14-141
Main Valvs Body
Disass€mbf y/lnspoction/R.sssembly .'.'.'.'.. -. -. 1 1-1 12
Secondsry Valve BodY
Disa$embfy/lnspoction/Rsassembly ......'.'.'.'. 11-111
Regulator Valve Body
Disa$embly/lnspoction/Rea3sembly ..........'... 14-1{5
Servo Body
Disassombly/lnsp€ction/Reassembly .".'........ 14-146
Lock-up Valv6 Body
Dis$s.mbf y/ln3poction/Rea$embly .'.. -. -..'.'.' 1 1-1 17
Mainsh!ft
Dkassembly/lnep€ction Reassembly ..'...'........ 14'148
Inspoction .............'..........'. l it-149
Countsrshaft
Disa$embly/lnspeqtion/Rea3sembly .......'...'.. 1a-l51
Dba$ombly/Re$s.mblY11-152
til-46
I rl-48
Troubleshooting Flowcharts
Electrical Troubleshooting ('9!t - 00 Models)
Troublsshooting Flowchart3
Lock-up Control Solenoid vslvo A/B AssemblY
RePlacoment
Shift Cont.ol Solenoid Valve A/B A3sembly
Inspestion
Ona-way Clutch
Disassembh/lrupoction/Rca$embly .. "'........ l4-155
Clutch
lllustlttcd Ind.x {A48A, B4RA Transmlssion) ..' 14-156
tustr.tod Index (MrnA Transmi$ionl ............ til-158
...................... 14-153
L
14-56
1+81'
14-105
1+105
Replacoment ......
Mainshaft/Countorshaft Spo€d Sonsors
Replacemsnt ......'."'........... lit'108
Hydraulic System
Symptom-to-Componeni Chart
Hydraulic Sydemr+109
t4-113
1+116
11-117
Rea$emblY
14-106 Difforrr ial
llhdraied Index........ t4-156
B.ckhrh ln3poction. 14-167
Boaring Roplacemont..-..........11-167
..... 14-108 Diftrrsniial Carrior Repl8cemeni .'.-.............'...' lil-168
Oil Sall Romovalt4-t 59
Oil Soal ln3tallstion/Sidc Clearance'......'.....'... 1'l'169
Torqua Convertcr Housing Boarings
Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
Counio6hatt Betring R.plscem.nt ..'...... ....... 14-173
Test.....,......14-106
14-107
14-160
11-162
11-171
11-175
Replacement
Test .....,.,..........
Road Te3t
Linear Solenoid AsssmblY
Stall Speed
lllustrated Indax
Transmission/End Cover'. ....
Transmission Hou3ing,.............'.'......'....""..-.-.. 11-128
Torque Conve.ter Housing/Valvo Body ........... 14-130
End Cover
14-itB Park Stop
1+119 In3pection/Adiustmsnt...'......'.'............'...."""'14-175
Transmbgion
Reassombly
11-122 Torquo Convertet/Drivr Plsie ............'.'............'.. . l4-182
Transmission
11.726 Inrtallation
Tranlmission Housing Boarings
Msinsh.ft /CounteEhaft Bearings
B!pltcomgnt
Rcvo.3s ldlor Gear
lnrtallation
Cooler Flushing ..
Shift Cabls
Test
Fluid Level
Checkin9 .........."..'.'.....
Changing
Pressure Testing
Transmission
Transmission
Rgmoval ..
lil-176
.'..........'.'.'..... 1'l-183
.... lil-187
11-132Adiustmont
RemovaUlnttallation1,1-190
lit-191Transmisgion Housing
Removal ... '.'...... ......'..... 14-l3il
Tolque Convgrter Housing/valvs Body
Rsmoval .........,...... ............. 14-136
Valve CaDs
Description .......'................. t 4'138
Shift lndicator Panel
Adiu3tmant ..'.................. 14-192
ATF Coolor Hoses
Connection ..,............,.,....... l'l-192
Shift Lever .,........

Pressure Testing
@I While testing, be caroful of th€ rotating front wheels.
. Make sure lifts, iacks, and satoty stands are placod properly (see section 1)'
CAUTION:
. Beforo iesting, be sure the transmission fluid is tilled to tho proper level'
. Warm up tho engine before testing'
1. Raise the vehicle (see section 1).
2. Warm up the engine, then stop the engine and connect a tachometer'
3. Connect the oil pressure gauges to each inspection hole.
TOROUE: 18 N.m (1.8 kgf'm, 13 lbnft)
cAUTloN: connact the oil pressuro gauges securely; be suro not to allow dust and other foreign Parlicles to entel
the inspestion holos'
A/T OIL PRESSURE GAUGESET w/PANEL07t06 - 0020400
A/T LOW PRESSURE GAUGE
SET WPANEL07406 - 0070300
A/T OIL PRESSURE HOSEADAPTER07Mru - PY0120(4 requiJedl
A/T OIL PBESSURE HOSE
2210 mmOTMAJ - PY4{)llA
14 roquircdl
Start the engine, and measure the respective ptessure as follows'
a Line Pressure
. 1st Clutch Pressure
. 2nd,3rd and 4th Clutch Pressure
Install a new washer and the sealing bolt in the inspection hole. and tighten to the specified torque'
TOROUE: l8 N.m (1.8 kgf'm,13lbf'ft)
NOTE: Do not reuse old sealing washers; always replace washers'
(cont'd)
14-119

Continuously Variable Transmission (CVTI
Special Tools ................ 14-194
Description .................... 14-195
Clutches/Reverse Brake/Planetary
Gear/Pulleys .......... 14-198
power Flow ..............,..... 14-200
Electronic Control SYstem(,96 - 98 Modets) ......14-203
Electronic Control System
('99 - oo Models) " 14-205
Hydraulic Control '....... 14-208
Hydraulic Flow .'..-.....'... '14-212
Park Mechanism .....-...'.' 14-222
Eleqtrical Systom
Component Locations'96 - 98 Models """"""' 14-224,99 - 00 Modets ............. 14-225
TCM Circuit Diagram ('96 - 98 Models) ............. 14-226
TCM Terminal Voltage/Measuring Condiiions ('96 - 98 Models) '.... 14-228
PcM Circuit Oiaqram{A/T Control System: '99 - 00 Models} ...--.... 14-230
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)
A/4 Control System .'.'...14-232
Troubleshooting Procedures ... . .... .....',........."' '14-234
Symptom-to-ComPonent Chart
Electrical System - '96 - 98 Models ......'..... '14-234
Electrical System -'99 - 00 Models ..'....-..-. '11-210
Electrical Troubleshooting
Troubleshooting Flowcharts('96 - 98 Models) """'11-242
Troubleshooting Flowchart
('99 - 0O Modets) ...... 14-265
Linear Solenoids/lnhibitor Solenoid
Test ......................... . ...... 14-29f
Drive Pulley/Driven Pulley/Secondary Gear
Shaft Speed Sensors
Replacement .........'...... .14-292
Start Clutch Control
Start Clutch Calibration Procedure ....... ....,. 14-293
Hydraulic SYstem
Symptom-to-ComPonent Chart
Hydraulic System '.'.......14-294
Road Test ............................ 14-296
Stall Speed
Test......................... ...... 14-294
Fluid Level
Checking/Changing ....... 14-299
Pressure Testing ................. 14-300
Lower Valve BodY AssemblY
Replacement ..........,... 14-302
ATF Filter
Removal/lnstallation ..... 14-303
Transmission
Transmission
Removal ........... . 14-304
lllustrated Index
Transmission/Lower Valve BodY
Assembly ................. 14-308
Transmission Housing/Flywheel Housing ... 14-310
End Cover/f ntermediate Housing ..........'.'.... 14-312
Transmission Housing/Lower Valve Body Assembly
Removal ..........'.... .. " 14-314
Transmission Housing/Flywhesl Housing
Removal ................. ........ 1+316
End Cover/lntermediate Housing
14-318Removal .........,...............
Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'..... 1 4-320
Forward Clutch
lltustrated Index ........................................ 14-321
Disassemblv .................. 14-322
Reassemblv , ,, . ',','......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection ..'.'....-... 14-324
Differential
lllustrated lndex ...,.....................,.,...-.-.-...'... 14-329
Backlash Inspection .-....14-329
Bearing Replacement ......'........'....'... ....'... 14-330
Differential Carrier Replacement ........'........ 14-330
Oil Seal Removal ........... 14-331
Oil Seal Installation/Side Clearance ....... . . 14-331
Flywheel Housing Input Shaft Oil Seal
Replacement .....,.... ...'.'.. 14-333
Transmission Housing Bearings
Driven Pulley Shaft Bearing
Replacenient ...................'. . ...................'.. 14-334
Secondary Gear Shaft Bearing
Reolacbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Secondary Gear Shaft BearingReo1acement..................,........................... 14-335
Ring Gear Bearing
Replacement......... ........ 14-336
Control Shaft Assembly
Removal/lnstallation ....................'........... 14-336
Transmission
Reassembly .................. 14-338
Flywheel/Drive Plate .. . ...... . ...... ... . ....-.....'.'...14-341
Transmission
lnstalation ..................... 14-348
Cooler Flushing .'......... 14-352
shift cable
Removal/lnstallation....'........." """ 14-354
Adjustment .......'........ 14-355
Shift Lever ........................,. 14'356
Shift Indicator Panel
Adjustment ................ 14-357
ATF Cooler/Hoses
lnsta llation ......,,...... .... 14-357

t
To STEERING GEARBOX
To STEERING GEAREOx
@ The fluid volume that flows thorough oil passage A
and the pressure djfference applied to the sub-valve
increase in proportion to the engine speed. The
sub-valve lowers overcoming the spring force, and
it stans to close the variable orifice to regulate the
discharge volume, When this happens, the fluid vol-
ume flowing to the steering gearbox decreases as
the engine speed increases. At the same time, the
flow control valve continues to control the fluid vol-
ume to the return Port,
@ As the engine speed increases funher, the pressure
difference at the sub-valve increases further as well.
The sub-valve then closes the variable orifice com-
pletely, regulating the discharge volume further.
When this happens, the fluid volume discharged
from the pump to the steering gearbox is regulated
and maintained at a given level until the engine
speed reaches the high speed range The flow con-
trol valve functions continues to control the fluid
volume to the return Port.
Pressure Relief
Pressure at the discharge side of the fixed orifice is
directed to the bottom of the flow control valve. When
the pressure builds up, the relief valve in the flow con-
trol valve opens to release the pressure at the bottom of
the valve. This allows the flow control valve to be
pushed back by the pressure difference, and the fluid
volume to the pump return port increases.
As explained above. the system keeps the pump dis-
charge pressure (relief pressure) from exceeding the
given level by controlling the volume of the fluid to the
pump relurn pon,
1.,DAMPING ORIFICE{Docreases excessiv€vibration in the valv6.)
17-19
)
RELIEF VALVE {Opan)
SUB.VALVE
FLOW CONTROL VALVE
/F ft>..\
'-€/K\A/A
o'.'to"5lo'#2"n af11\D7
FLOW CONTROL VALVE

/
Uneven or rough steering
Steering wheel kicks back
during wide t!rns.
ll,
)
Adjust the rac* guide (see page 17-3).
lf the problem is not corrected bY
adjusting the rack guide, replace
the gearbox.
Adiust the belt tension. Feplace the
belt, il necessary (see Page 17 32).
lfthe engine stalls when the wheel
is turned while car is stopped or
moving at low speed, adjust the
idle spe€d (see section 11)
ldle speed low or erratic.
Check power sleering fluid level lf
the level is excessively low, check
lor leaks in the system. Add lluid
to the specified level.
Air in reservoir, or check Powersteering Iluid level.
lf ltuid level is OK, check O-rings
and seals on both ends of thepump inlet hose, and the P/Spump housing mating surfaces
and the pumP shaft oil seal for
suction leaks. RePlace Parts as
nocessary.
Adjust the belt tension (see Page17 32)or replace belt.Pump belt sliPPing on PLrlleY(pump stops momentarilY)
Check if pump press{rre is normal
and the gauge needle travel is 500
kPa (5 kgl/cm?, 7l Psi) or less.
Chock the flow control valve if the
needle travel exceeds 500 kPa (5
kgflcm', 71 Psi). l{ the flow control
valve is normal, replace the PumPas an assemoly.
Install the power steering pressure
gauge, Close the Pressure contrcl
valve fully and m6ssure the PumPpressure {s€e page 17-34}.
17 -25,