Stall test HONDA CIVIC 1996 6.G Owner's Manual

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

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 .,........

Shift Control Solenoid Valve A/B Assembly
Test
1. Disconnect the 2P connector from the shift control
solenoid valve A,/B assemblv.
SHIFT CONTROLSOLENOID VALVE A/B
ASSEMBLY
N4easure the resistance between the No. 1 terminal(solenoid valve A) of the shift control solenoid valve
connector and body ground, and between the No. 2
terminal (solenoid valve B) and body ground.
STANDARD: 12 - 25 O
Replace the shift control solenoid valve assembly if
the resistance is out of specification,
lf the resistance is within the standard, connect the
No. 1 te.minal of the shift control solenoid valve
connector to the battery positive terminal. A clicking
sound should be heard. Connect the No. 2 terminal
to the battery positive terminal. A clicking sound
should be heard. Replace the shift control solenoid
valve assembly if no clicking sound is heard.
14-106
Replacement
NOTE: Shift control solenoid valves A and B must be
removed/replaced as an assembly.
1. Remove the mounting bolts and shift control solenoid
valve A,/B assembly.
5xL0mm12 N.m(1.2 kgf.m,8.7 lbf.ft)CONNECTOR BRACKET
FILTER/GASKETBeplace.Clean the mounting surfaceand fluid passages.
Clean the mounting surface and fluid passages of
the shift control solenoid valve assembly, and
install a new shift control solenoid valve Ay'B with a
new filter/gasket and the clamp bracket.
Check the connector for rust. dirt or oil. and recon-
nect it securelv,

Road Test
NOTE: Warm up the engine to normal operating tem peratu re (the rad iator fan comes on )'
1. Apply parking brake and block the wheels. Start the engine, then shift to E position while depressing the brake
Dedal, Depress the accelerator pedal and release it suddenly. The engine should not stall'
2. Repeat same test in E Position.
3. Test-drive the vehicle on a flat road in the E position. Check that the shift points occur at approximate speeds shown
in the table. Also check for abnormal noise and clutch slippage.
NOTE: Throttle position sensor voltage represents the throttle opening
a. Unbolt the PCM for road testing; refer to page 14-50.
b. Setthedigital multimeter to check the th rottle position sensor voltage between PCM terminals;
. '96 - 98 models: D1 {+) and A9 (-) or 422 (-}.
. '99 - 00 models: C27 (+) andB20t-) orB22{-}.
BACKPROBE ADAPTER
BACKPROBE SET07sAz - 001oq)A{two requiredl
DIGIIAL MULTIMETERlCommercially available)KS-AHM-32-003,or equivalenl
'96 - 98 Modelsr
Wire side ol temale terminals
PCM CONNECTORS
B t25Pl c (31P)
LG1 IBRN/BLK)
I (25P1c (31P}
A t32PtD (16P)
Wire side ol female terminals
'9!t - 00 Models:
1+113

Stall Speed
Test
CAUTION:
. To prev€nt transmission damage, do not t6st stall speed for more than ro sgconds at a time.. Do not shift the levor while raising the engine speed.. Bo sule lo remove the pressure gauge betoro testing stall speed.
'1. Engage the parking brake, and block the front wheels.
2. Connect a tachometer to the engine, and start the engine.
3. Make sure the Ay'C switch is OFF.
4. After the engine has warmed up to normal operating temperature (the radiator fan comes on). shift into E position.
5. Fully depress the brake pedal and accelerator for 6 to g seconds, and note engine speed.
6. Allow two minutes for cooling, then repeat the test in @ and @ positions.
NOTE:
. Stall speed tests should be used for diagnostic purposes only,. Stall speed should be the same in o., E and E positions.
Stall Spsed RPM:
Specification: 2.700 rpm
Service Limit: 2,550 - 2,850 rDm
TROUBLEPROBABLE CAUSE
. Low fluid level or ATF pump outDur. Clogged ATF strainer. Pressure regulator valve sluck closeo. Slipping clutch
. Slippage of 4th ctutch
. Slippage of 2nd clutch
. Slippage of lst clut"tr or. t"t g""io*-*"y "lut"h
Stall rpm high in D., E and E positions
Stall rpm high in El position
Stall rpm high in E posirion
Stall rpm high in E position
Stall rpm low in LDa . El and E positrons. Engine output low. Torque converter one-way clutch slipping
14-116

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

Transmission
Installation {cont'd)
Connect the lock-up control solenoid connector. andinstall the transmission ground cable.
6 x '1.0 mm12 N.m {1.2 kgf.m, 8.7 lbl.ft}
LOCK.UP CONTROLSOLENOID CONNECTOR
Connect the staner cables on the staner motor. andinstall the cable holder.
NOTE; When installing the starter cable terminal.make sure that the crimped side of the ring terminalis facing out (see section 23).
6x1.0mm12 N.m 11.2 kg{.m.8.7 tbtftl
{0.9 kg'f.m, 7 lbf.ftl
TRANSMISSIONGROUND CABLE
b
14-186
STARTER CAELE
24. Installthe intake air duct.
D16Y7 engine:
Install the intake air duct and the resonaror.
D16Y8 engine:
lnstall the intake air duct and the air cleaner hous_ang assembly.
25. Refill the transmission with ATF (see page 14_1.18).
26. Connect the positive (+) cable first. then the nega-tive (-) cable to the battery.
27. Check the ignition timing (see section 23).
28. Start the engine. Set the parking brake, and shift thetransmission through all gears. three times. Checkthe shift cable adjustment (see page 14_190).
29, Check the front wheel alignment (see section 1g).
30. Let the engine reach operating temperature (thecooling fan comes on) with the transmission in Nor @ position, then turn it off and check the fluidlevel (see page 14- 7).
31. Road test as described on pages 14-113 thru ,14_116.

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

Troubleshooting Flowchart - Shift Control System
NOTE: Record all freeze data before you troubleshoot.
Po$ible Cause
Faulty 3hift control systemOgD ll Scan Tool indicates Code
P'1890.Self-diagnosi3 E indicator light
indicates Code 42.
Check for Anolhet Code:
Check whether the E indicator
light indicates another code.
Pertorm the TroubleshoolingFlowchrrt to. th€ indicet.d
Codelsl.
ls the E indicator light indi
cate another code?
Check Stall Speed RPM:Measure the stall speed RPM(see page 14-298).
ls the stall speed over 3,500 rpm?
ls the slall speed below 2.0o0 rpm)
Test-drive and Check E ngine
Speed:1. Drive the vehicle at 30 mPh(50 km/h) constantlY for sev_
eral manutes.2. Check the engine speed
ls the engine speed within the
specification (see page 14 296
and 14 297\?
14-259

Troubleshooting Flowchart - Shift Control System
NOTE: Record allfreeze data before you troubleshoot
Possible cause
Faultv shift control svstem' OBD ll Scan Tool indicates Codo
P1Ato.. Self-diagnosis E indicator light
indicatos Code 42.
Check for Anoth€r Code:Check whether the E indicator
light indicates another code.
P€rform the Tloubleshooting
Flowchart for the indicated
Code(sl.
ls the E indicator light indi
cate another code?
Check Stall Speed RPM:
Measure the stall sPeed RPM(see page 14-298).
ls the stall speed over 3,500 rpm?
ls the stall speed below 2,000 rpm?
Test-drive and Check Engine
Speed:L Drive the vehicle at 30 mph
150 km/h) constantly for sev-
eral mlnutes.2. Check the engine speed
ls the engine speed within the
specification (see Page 14'296
and 14'297)?
14-245