ac system HONDA CIVIC 1999 6.G Workshop Manual

Glutch Master Gylinder
IRemovaUlnstallation
CAU'NON:
. Do not sDill brake lluid onthevehicle;it may damage
the paint; if brake fluid does contact the paint, wash
it off immediatelY with water.
. Plug the end ofthe clutch line and reservoir hos€ with
a shop towelto prevent brake tluid from coming out
1. The brake tluid can be removed from the clutch
master cylinder reservoir with a syringe
2. Disconnect the clutch line and reservoir hose from
the clutch master cylinder.
19N.m 11.9 kgf.m,14 tbf.ttl
[.
3. Pry out the lock pin, and pull the pedal pin out
the yoke. Remove the nuts
NUTS8 x 1 .25 mm13 N.m {'1.3 kgt.m,9.4lbf ft)
)
of
CLUTCH LINE
iffi,
4. Remove the clutch master cylinder.
CLUTCH MASTER CYLINDER
lnstall the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system {see page
12-61,
12-5

Slave Gylinder
Removal/lnstallation
CAUTION:
. Do not spill brake tluid on the vehicle; it may damage
the paint; if brake fluid does contact th€ paint, wash
it off immodiatoly with water,
. Plug the end ot the clutch line with a shop towel to
prevsnt brake fluid from coming oul.
-61'srp", High Temp Urea crease (p/N
08798 - 90021.
: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch line from the slave cvlinder.
2. Remove the slave cylinder from the clutch housing.
12-6
3. Install the slave cylinder in the reverse order of
removal.
NOTE: Make sure the boot is installed on the slave
cvlinder.. CLUTCH LINE15 N.m (1 .5 kgf.m, 1 1 lbf.It)
SLAVE CYLINDER
-G4(P/N 08798- 90021
8 x 1.25 mm22 N.m 12.2 kgl.n,16 lbl.lt)
:^..:i!!!!! :l
(Brak€ AssemblyLubol
Bleed the clutch hydraulic system.
a Attach a hose to the bleeder screw, and suspend
the hose in a container of brake fluid.
. Make sure there is an adequate supply of fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
. Refill the clutch master cylinder with fluid when
done.
. Always use Genuine Honda DOT 3 Brake Fluid.
Using a non-Honda brake fluid can cause corro-
sion and decrease the life of the system.
. Confirm clutch operation, and check for leaking
flu id.

Troubleshooting
Reverse Gear Noise Reduction System
Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.
The resulting speed difference between mainshaft and reverse idler gear produces gear noise.
The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting
into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate. This causes the sth synchro set
to stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less
gear norse.
NOTE: This system is not a fully-synchronized gear noise reduction system.
Therefore, you may hear gear noise when
O you shift into reverse with the vehicle not yet completely stopped.
@ you shift quickly into reverse during fast idling.
-
Gear noise is oresent when shift-ing into reverce after the engineis started.
Test-drive the vehicle.
ls the gear noise present whenshifting into 5th gear?Beplace the 5th synchro hub and3leeve e3 a set,
Measure the clearance between5th shift fork and 5th synchrosleeve {see page 13'26).
ls the clearance 1.0 mm (0.04
in) or less?
Measure the MBS shift piece pin(see page 13-27).
ls ( 6.8 mm (0.27 in) or more?Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4

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 .,........

Electronic Control SYstem
The electronac controt system consrsts of a Powertrain control Module (PcM), sensors, a Iinear solenoid and four solenoid
valves, shifting and lock-up are electronically controlled for comfortable driving under all conditions The PCM is located
below the dashboard, under the front lower panel on the passenger's side
PGM-FIControl Sy3tem
A/T Control SYstom
Shift Control
Lock-uD Control
14-13

Description
Electronic Control System (cont'd)
Shift Control
The PCM instantaneously determines which gear should be selected by various signals sent from sensors, and actuatesthe shift control solenoid valves A and B to control shifting. Also. a Grade Logic Control System has been adopted to con-trol shifting in E position while the vehicle is ascending or descending a slope, or reducing speed.
PoshionGearShift Control Solenoid
Vslve A
Shift Control Solenoid
Valve B
8,tr
1stOFFON
2ndONON
3rdONOFF
E4thOFFOFF
tr2ndONON
E-ReverseONOFF
*See page 14-31 for reverse inhibitor control description.
Lock-up Control
From sensor input signals, the PCM determines whether to turn the lock-up ON or OFF, and activates lock-up controlsolenoid valve A and/or B accordingly. The combination of driving signals to lock-up control solenoid valves A and B andthe linear solenoid pressure is shown in the table below.
Lock-up ConditionsLock-up Control
Solenoid Valvo A
Lock-up Control
Solenoid Valve B
Linoar Solonoid
Prggguro
Lock-up OFFOFFOFFHigh
Lock-up, HalfONDuty operation
OFF * ONLow
Lock-up, FullONONHigh
LOCK-Up
during decelerationONDuty operation
OFF - ON
a
14-14

GRADE LOGIC CONTROL SYSTEM
How it works:
The pCM compares actual driving conditions with driving conditions memorized in the PCM, based on the input from the
vehicle speed sensor, the throttle position sensor, the barometoric pressure sensor, the engine coolant temperature sensor,
the brake switch signal, and the shift lever position signal, to control shifting while a vehicle is ascending or descending a
slope, or reducing speed.
SIGNALS OETECTED
O.iving Resi3lence
Judgemenl ot Conirolling Arca
. Ascending mod€
lFuzzy loqicl. Gradual Ascending mode' Ste€p Ascending mode. Oescending mode. Gr.du.l Descending mode. Steep D6cending mode
14-15

Description
Electronic Control System {cont'dl
Ascending Control
When the PCM determines that the vehicle is climbing a hill in E position, the system oxtends the sngagement area of2nd gear and 3rd gear to prevent ths transmission from fr€quently shifting between 2nd and 3rd gears, and between 3rdand 4th gears, so the vehicle can run smooth and have more power when needed. There are two ascending modes withdifferent 3rd gear driving areas according to the magnitude of a gradient stored in the pCM.
NOTE:
. The PCM memory contains shift schedules between 2nd and 3rd gears, and between 3rd and 4th gears that enable thePCM's fuzzy logic to automatically select the most suitable gear according to the magnitude of a gradient. Fuzzy logic is a form of artificial intelligence that lets computers respond to changing conditions much like a humanmind would,
Dssconding Control
When the PCM determines that the vehicle is going down a hilt in E position, the shift-up speed from 3rd to 4th gearwhen th€ throftle is closed becomes faster than the set speed for flat road driving to widen the 3rd gear driving area.This, in combination with engine braking from the deceleration lock-up, achieves smooth driving when the vehicle isdescending. There are two descending modes with different downshift (4 - 3) schedules according to the magnitude of agradient stored in the PCM. When the vehicle is in 4th gear, and you are decelerating on a gradual hill, or when you areapplying the brakes on a steep hill, the transmission will downshift to 3rd gear. When you accel6rate, the transmission willthen return to 4th gear.
ASCENDING MODEDESCENDING MODE
4TH SHIFTING
L.
F
CHARACTERISIICSCONTROL AREA
ff.1"11", vehicr. 3pe€dff;Tlr., vohicre speed
GRADUAL ASCENOINGCONTROL AREA
Docel6ration Control
When the vehicle goes around a corner. and needs to first decelerate and then accelerate. the rcM sets the data for decelerationcontrol to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds above 26 mph(41 km/h), the rcM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration.
14-16

Description
Electronic Control System (cont'dl
Circuit Diagram and Terminal Locations -'99 - O0 Models
GNTONSWICH,,--b. rcj
LI
LOCK.UPCONIFOLSOLEI\Q D VALVE A
LOCK UP CON'IROLSOLENODVALVEB
SH FI CONTROL
SHIFTCONTFOLSOLENOIDVALVEE
L NEAF SOLEIOIO
PG2
IGP2
v3u
vcc2
sc2
6NII ON SWICH
14-18

Hydraulic Control
The hydraulic control system is controlled by the ATF pump, valves, accumulators, and electronically controlled solenoids'
TheATFpUmpisdrivenbysp||nesontheendofthetorqueconverterWhichisattachedtotheengine.F|uidfromtheATF
pumpf|owsthroughtheregu|atorva|vetomajntainspecifiedpressurethroughthemainva|vebodytothemanuaIva|ve'
directingpressuretoeachofthec|utches.Theva|vebodyinc|udesthemainvaivebody,theregu|atorvalvebody,the
|ock-upva|vebody,thesecondaryVa|vebody,theservobody,theIinearso|enoid,theshiftcontro|so|enoidva|velVB
assembly, and the lock up control solenoid valve A/B assembly. The shift control solenoid valve Ay'B assembly and the lin-
ear solenoid are bolted on the outside of the transmission housing. The lock-up control solenoid valve A,/B assembly is
bolted on the outside of the torque converter housing
SHIFT CONTROLSOLENOIO VALVE A/8
ASSEMBLY
LINEAR SOLENOID
SERVO BOOY
REGULATORVALVE BODY
VALVE
VALVE BOOY
(cont'd)
CONTROLSOLENOID VALVE A/BASSEMBLY
ATF PUMP GEARS
14-19