idle adjust HONDA CIVIC 1996 6.G Owner's Manual

Symptom-to-Component Chart
Hydraulic System (cont'dl
G.
n,
set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
lf the clutch pack is seized or is excessively worn. inspect the other clutches for wear, and check the orificecontrol valves, CPC valve and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lmproper alignment or main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
lf the l st clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged. lf the 4th feed pipe is danFaged or out of round, replace the right side cover.
Replace the mainshaft if the bushing for the 1st feed pipe is loose or damaged. lf the 1st feed pipe is darn-aged or out of round, replace it.
A worn or damaged sprag clutch is mostly a result of shifting the transmission inthe wheels rotate in reverse, such as rocking the vehicle in snow.
or E position while
Inspect for damage and wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear u nder pin ion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1,2,3 and 4 if worn or damaged. lf transmission makes a clicking, grinding orwhirring noise,also replace mainshaft 4th gear, reverse idler gear. and countershaft 4th gear in addition to 1, 2, 3 or 4.lf differential pinion shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughlyclean transmission, flush torque converter, cooler and lines.lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and final drivengear.
Be very careful not to damage the torque converter housing when replacing the main ball bearing, you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the oroper roors.
Install the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
See flushing procedure, page 14-187 and 188.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the l-2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission hasno 1st gear.
lf the znd orifice control valve is stuck. inspect the 2nd and 3rd clutch oacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch oacks for wear.
lf the clutch pressure control valve is stuck closed, the transmission will not shift out of 1st gear.
lf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Inspect the frame for collision damage.
14-112

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.

Symptom-to-Component Chart
Hydraulic System
*1: Some gear noise is normal in the Lll position due to planetary gear action.
14-294
SYMPTOMCheck these items on the PBOBABLE CAUSE List
Engine runs, but vehicle does not move in any position.'t,2,3,4,5,6,7,8,9, 10, 20, 34, 35, 36, 38, 41
Vehicle does not move in @, [. p positions.10,11, 12, 20, 41
Vehicle does not move in E position.5, 'to, 11, 12, 17, 1A, 19, 20,39, 41
No shift to higher ratio,9, 13, 14. 15, 16,35,37,40
Poor acceleration.9, 13,'t4,'t5,16. 20, 35, 37, 38, 40
Flares on moving.9,'t0, 20, 2't, 35, 36, 38, 40, 42
Excessive shock when depressing and releasing.^^alA/.r^r ^A.1. I9, 10, 20, 2'1, 35, 36, 3A, 42
No engine braking.9,20,21,35,36,38
Vehicle does not accelerate in lll position.9, 17, 18, 19, 20. 35, 36, 38
Vehicle moves in E position.
(Shift cable adjustment is proper).10, 22,23
Late shift from N position to E position, and from Eposition to E position.'10,11, 12,22, 41
Late shift from E position to E position. and from Eposition to N position.1l,'t2, 17, 18,22, 41
Engine stops when shifted to E position from E position.9, 10,20,35,37,34, 42
Engine stops when shifted to E position from I position.9, 18, 19,20,25,26,35,37,38, 42
Noise from transmission in @ position.rl5, 17, 18, 't9,25,26
Excessive idle vibration.2,3,4,21,24
Noise from transmission in @ and @ positions.2,3, 19,24,25,2A
Hunting engine speed.16, 35, 37, 38
Vibration in all position.8, 2a
Shift lever does not operate smoothly.11,29, 4'l
Transmission will not shift into lll position or transmis-
sion cannot be removed from E position.11 , 29, 30, 31, 32,33
Vehicle does not accelerate to more than a certain speed.9, 10, 14, 15,'t6,20,35,37
Excessive shock on starting off.38, 42
Flares on accelerating at low speed.20, 21 ,38, 42
Excessive vibration in E, E, tr, E positions.20,21,38, 42
Low engine speed in E. E. tr. E positions.20,21,38,42
Stall speed high.10,20,38
Stall speed low.9, 20, 27 ,37 , 38
Judder on starting off.20, 43

/
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,

Inspection and Adjustment
Steering Operation
Place the front wheels in the straight ahead position,
and measure the distance the steering wheel can beturned without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm l0 - 0.39 inl
lf the play exceeds the service limit. perform rack guide
adjustment (see page 17-33).
lf the play is still excessive after rack guide adjustment.inspect the steering linkage and gearbox as describedon the nel(t pag€.
ROTATIONAL PLAY
17-30
Power Assist Gheck with
Vehicle Parked
1. Check the power steering fluid level (see page 17-33) and pump belt tension (see page 17-32).
2. Start the engine, allow it to idle. and turn the steer-ing wheel from lock-tolock several times to warm
up the fluid.
3. Attach a spring scale to the steering wheel. With theengine idling and the vehicle on a clean, dry floor,pull the scale as shown and read it as soon as thetires begin to turn.
The scale should read no more than 29 N (3.0 kgf.
6.6 lbf). lf it reads more, check the gearbox andpump,
D0

IRack Guide Adjustment
NOTE: Perform rack guide adjustment with the wheels
in the straight ahead Position.
1. Loosen the rack guide screw locknut with the
cialtool.
'96 - '97 models:
Loosen the rack guide screw
'98 - '00 models:
Remove the rack guide screw and remove the old
sealant off of the threaded section.
Apply new sealant all around the threads. Loosely
installthe rack guide screw
Tighten the rack guide screw to 25 N'm (2.5 kgf'm.
18 lbf.ft), then loosen it.
Retighten the rack guide screw to 3 9 N'm (0.4 kgim,
2.9 lbf.ft), then back it off to specified angle.
Specified Return Angle: 20" max.
Tighten the locknut while holding the rack guide
screw.
Check for tight or loose steering through the com-
plete turning travel.
Perform following insPections:
. Steering operation (see page 17-30).
. Power assist with vehicle parked.
4.
LOCKNUT WRENCH, 40 mm
lr
17-33
Fluid Replacement
Check the reservoir at regular intervals, and add fluid as
necessary.
CAUTION: Always us€ Genuine Honda Power Stearing
Fluid-V or S. Using any other type of power sto€ring
tluid or automatic transmission lluid can cause
increased wear and poor steering in cold weathor.
SYSTEM CAPACITY:
0.85 liter 10.90 US' qt,0.75 lmp'qt)
at disassembly
RESERVOIR CAPACITY:
0.4 liter (0.42 US. qt, 0.35 lmP.qt)
LEVEL LINE
LOWER LEVEL LINE
1. Raise the reservoir, then disconnect the return nose.
2. Connect a hose of suitable diameter to the discon-
nected return hose, and put the hose end in a suit-
able container.
CAUTION: Take care not to spill tho fluid on the
body and parts. Wipe off any spill€d fluid at oncs'
3. Start the engine, let it run at idle, and turn the steer-
ing wheel from lock-to-lock several times When
fluid stops running out of the hose, shut off the
engine, Discard the fluid.
4. Reinstall the return hose on the reservoir'
5. Fill the reservoir to the upper level line.
6. Start the engine and run it at fast idle, then turn the
steering trom lock-to-lock several times to bleed air
trom the system.
7. Recheck the fluid level and add some it necessary.
CAUTION: Do not fill the reservoir beYond the
upper l€vel line.
HOSE

lnspection and Adjustment
Pump Pressure Check
Check the fluid pressure as follows to determine
whether the trouble is in the pump or gearbox.
NOTE: First check the power steering fluid level andpump belt tension.
CAUTION: Disconnect the high pr$sure hos€ with care
so as not lo spill the power sieering tluid on tha frame
and other parts.
1. Disconnect the outlet line from the Dumo outlet fit-
ting, then installthe P/S joint adaptor (pump) on the
Dumo outlet.
2. Connect the P/S joint adaptor (hose) to the power
steering pressure gauge, then connect the outlet
hose to the adaptor.
3. Install the power steering pressure gauge to the P/Sjoint adaptor (pump) as shown.
ourlEr HosE FnrNo ,t"ll lrilu"ott
P/S JOINT ADAPTOB IHOSEI07RAK - S0i10l2rol07RAK- 50{{)120
P/S PRESSURE GAUGE07406 - 001000Aor07406 - 0010001
4. Open the shut-off valve fully.
5. Open the pressure control valve fully.
17-34
(Pa.t of tooll11 N.m11.1 kgt m, 8 lbf.ftl
PRESSURECONTROL VALVE
SHUT.OFFVALVE
PUMP OUTLETFITTING
6 x 1.0 mm BOLTlPart of tool)11 N.m11.1 kgf m, 8 lbtftl
7.
Start the engine and let it idle.
Turn the steering wheel from lock-to-lock several
times to warm the fluid to operating temperature.
Measure steady-state fluid pressure while idling. If
the pump is in good condition, the gauge should
read less than 1500 kPa (15 kgf/cmr, 213 psi).
lf it reads high, check the outlet line or valve body
unit (see General Troubleshooting 17-22).
Close the pressure control valve, then close the
shut-off valve gradually until the pressure gauge
needle is stable. Read the oressure.
lmmediately open the pressure control valve fully.
GAUTION: Do not keep lhe prossure control valve
clos€d more then 5 soconds or the pump could be
damagod by over-heating.
lf the pump is in good condition, the gauge should
read at least 6,400 - 7,400 kPa (65 - 75 kgflcm,, 920 -
1,070 psi). A low reading means pump output is too
low for full assist. Repair or replace the pump,
9.
P/S PBESSURE GAUGE07{16 -@1@OA
oi
SI{UT.OFF VALVE

)
1?
12, Install the steering joint cover with the clamps and a
clrp.
Reconnect the tie-rod ends to the steering knuckles,
tighten the castle nut ('96 -'97 models) or nut ('98 -
'OO models) to the specified torque, and install new
cotter plns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint tapered
section and threads.
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening {,96 -'97 models only).
COTTER PINSReplace.On reassembly, bend
the cotter Pin 6s shown.'96 -'97 models:'98 -'00 mod€ls:
tr
CASTLE NUT40 - a8 N'm(4.0 - 4.8 kgf'm,29 - 35 lbf.ftl
NUT&l N.m{a.5 kgf'm, 33 lbl'ftl
NE-ROD END
(l-,
17-67
14.
15.
16.
17.
18.
Install the exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
lnstall the front wheels
Fill the system with power steering fluid, and bleed
air from the system (see page 17-331
After installation, perform the following checks
. Start the engine, allow it to idle, and turn the
steering wheel from lock-tolock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-39).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equallv

Compressor (SANDENI
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioner
work for a few minutes. then shut the engine off.
Disconnect the negative cable from the battery.
Recover the refrigerant with a recovery/recycling/
charging station (see page 22-27l..
Remove the bolts, then disconnect the suction and
discharge lines from the compressor.
NOTE: Plug or cap the lines immediately after dis-
connecting them to avoid moisture and dust con-
tamination.
6xl.0mm
Remove the condenser (see page 22-44).
NOTE: Do not disconnect the discharge hose from
the condenser.
Remove the power steering pump belt (see section
17 t.
22-30
24 N.m l2.ia kgt.m, 17 lbf.ftl
7. Loosen the center nut of the idler pulley and the
adjusting bolt. then remove the A,/C compressor belt
from the pulleys. Remove the two mounting bolts
from the left front mount, then remove the ly'C com-pressor belt by passing it through the gap befiiveen
the bodv and the left front mount.
ADJUSTING BOLT
1.0 x 1.25 mmaa N.m 14.5 kgf,m, 33 bnft)
8. Remove the four mounting bolts and the compressor.
CENTER NUT
COMPRESSOR

Compressor (DENSO)
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioning work
for a few minutes, then shut the engine off
Disconnect the negative cable from the battery'
Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271
Remove the each bolt, then disconnect the suction
and discharge lines from the compressor' Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contaminatlon.
6 x '1.0 mm9.8 N.m (1.0 kgf m,7.2 lbfft)
Remove the condenser, but do not disconnect the dis-
charge hose from the condenser (see page 22-441'
Remove the power steering pump belt (see sectron
17]-.
7. Loosen the pivot bolt of the idler pulley bracket and
the adjusting bolt. then remove the A,/C compressor
belt from the pulleys. lf necessary, remove the mount-
ing bolts from the left front mount. then remove the
fuC compressor belt through the gap between the
bodv and the left front mount.
'10 x 1,25 mm4,0 N.m (,1.5 kgf'm. 33 lbt ftl
Disconnect the compressor clutch connector, then
remove the mounting bolts and the compressor'
PIVOT BOLT10 x 1.25 mm4,1 N.m (4.5 kgt'm,33 lbfft)
COMPRESSOR
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37