hose HONDA CIVIC 1996 6.G Manual PDF

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Evaporative Emission (EvAPl Two Way Valve T6ting
'99 - 00 modols:
'L Remove the fuel tank (see page 11-242).
2. Remove the vapor line {rom the EVAP two way
valve (located above the EVAP control canister), and
connect it to a T-fitting from vacuum gauge and
vacuum pumo as snown,
VACUUM/PRESSUREGAUGE0 - il in.Hg07JAZ - 001(x)08
ry(L
"*'"""_,";f1
T.FITTING
Apply vacuum slowly and continuously while watch-
ing the gauge.
The vacuum should stabilize momentarily at 0.8 -
2.1 kPa {6 - 16 mmHg, 0.2 - 0.6 in.Hg).
lf the vacuum stabilizes (valve opens) below
0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa
(16 mmHg, 0.6 in.Hg), install a nsw valve and retest.
Move the vacuum pump hose from the vacuum fit-
ting to the pressure fitting, and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.
GAUGE,0 - 30 in.Hg4973X - (Xl -
xxxxx
J.
5. Slowly pressurize the vapor lin€ while watching the
gauge.
The pressure should be stabilize momentarily
above 1.0 kPa (8 mmHg, 0.3 in.Hg).
. lf the pressure momentarily stabilizes (valve
opens) above 1.0 kPa (8 mmHg, 0.3 in.Hg), the
valve is OK.
. ll the pressure stabilizes below 1.0 kPa (8 mmH9,
0,3 in,Hg), install a new valve and retsst.
(cont'd)
11-295

Emission Gontrol System
Evaporative Emission (EVAP) Controls (cont'dl
ORVR Vent Shut Valve Test
Float Test
1. Make sure the fuel tank is less than half full.
2. Remove the fuel fill cap to relieve the fuel tank pres-
sure, then reinstall the cap.
3. Remove the fuel hose joint protector. Disconnect
the ORVR vapor recirculation hose, and connect a
vacuum pump to the vapor recirculation hose.
ORVR VAPOERECIRCULATION
VACUUM PUMP/GAUGE,0 - 30 in.H9A973X - 041 -
xxxxx
Plug the hose port.
Apply vacuum to the ORVR vapor recirculation
nose.
. lf the vacuum holds, replace the ORVR vent shut
valve {see page 11-297).
. lf the vacuum does not hold, the float is OK.
4.
11-296
Vatve Tcst
1. Make sure the fueltank is lessthan halffull.
2. Remove the fuel fill cap.
3. Remove the fuel hose joint protector. Disconnect the
ORVR signal hose.
ORVRSIGNALHOSE
Disconnect the vacuum hose from the EVAP control
canister. and then plug the port with a plug.
VACUUMPUMP/GAUGE,0 - 30 in,HgA973X-041-XXXXX
CONTROLCANISTERVENT SHUTVALVE
Disconnect the vacuum hose from the EVAP control
canister vent shut valve, and connect a vacuum pump
to the vacuum hose,
Pump the vacuum pump 80 times.. lf the vacuum holds, go to step 7,. lf thevacuum does not hold, goto step9.

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7. Connect a second vacuum pump to the OBVR signal
nose.
VACUUM PUMP/GAUGE.0 - 30 in.HgA973X - 041 -
xxxxx
Apply vacuum (1 pump) to the ORVR signal hose,
then check the vacuum on the pump in step 6.
. lf the vacuum holds, replace the ORVR vent shut
valve.
. lf the vacuum is released, the ORVR vent shut
valve is OK.
Disconnect the ORVR quick disconnect from the EVAP
canister, then plug the port on the canister.
Reapply vacuum (80 pumps).
. lf the vacuum holds, reDlace the ORVR vent shut
valve,
. lf the vacuum does not hold, inspect the EVAP can-
ister vent shut valve O-ring. lf the O-ring is OK,
replace the EVAP canister and repeat step 4.
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I
11-297
ORVR Vent Shut Valve Replacement
1. Remove the fuel tank (see page 1 1-242).
2. Remove the ORVR vent shut valve from the fuel tank.
3. lnstall oarts in the reverse order of removal.

lllustrated Index
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NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
. lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6)
. Inspect the hoses for damage, leaks, interference, and twisting
'RESERVOIF TANK
ASSIST SPRING
LOCK PIN
5x1,0mm9.8 N.m (1.0 kgf.m,7.2 tbtftl*CLUTCH LINE15 N.m {1.5 kgJ m,11 tbt.ft)
RELEASE BEARINGRemoval/lnspection, page 12-1 1Installation, page 12-'12
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12 5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
FLYWHEELInspectaon, page 12IReplacement, Page 12-9
CLUTCH DISCRemoval/lnspection, page 1 2-8
lnstallation, page 12-'10
'12 x 1.0 mm118 N.m {12.0 kgt'm,86.8lbfft)
PBESSURE PLATEBemoval/lnspection, page 12 7Installation, page 12''10
8 x 1.25 mm22 N m (2.2 kgf.m, 16lbf ft)
ISLAVE CYLINDERRemoval/lnstallation, page 12_6
12-3

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.

Transmission Assembly
l
,
{
Removal
@Make sure iacks and safoty stands are placad plop-
erly (3ee section l).
Apply parking braks and block rear wheels so car
will not roll off stands and fall on you while working
under il.
CAUTION: Us6 fonder cove6 to avoid damaging painted
sudaces.
Disconnect the negative (-) cable from the battery,
then the positive (+l cable.
Drain the transmission oil. then reinstall the drain
plug with a new washer (see page 13-47).
Remove the intake air duct and the air cleaner hous-
ing assembly (see s€ction 5).
Disconnect the back-up light switch connector and
the transmission ground wire.
Remove the lower radiator hose clamp from the
transmission hanger B.
L
8 x 1 .25 mm22Nm12.2kgl'm,
LOWER RADIATORHOSE CLAMP
16 rbtft)
13-48
7.
Bemove the wire harness clamps.
Disconnect the starter motor cables and the vehicle
speed sensor (VSS) connector.
8 x 1.25 mm8.8 N.m (0.9 kgf.m,6.5 tbtftl
STARTERMOTORCABLES
8. Remove the clutch line bracket and the slav6 cylin-
oer.
NOTE: Do not operate the clutch pedal once the
slave cylinder has been removed.
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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 .,........

Special Tools
l.- a
Ref. No. Tool Number
o,6'\
€)
@)
@-
@
@
o
@
@
@
@..
@
@
@
@
@
07GAB - PF50101
07GAE - PG40200 or
OTGAE - PG4O2OA
07HAC - PK4010A
07JAD - PH80101
07JAD - PH80200
07LAE - PX40100
07PM - 0010100
07sM - 0010004
OTMAJ - PY4O1 1A
07MAJ - PY40120
07406 - 0020400
07406 - 0070300
07736 - A010004
07746 - 0010500
07746 - 0010600
07746 - 0030100
07749 - 0010000
07947 - 611501
Mainshaft Holder
Clutch Spring Compressor Bolt Assembly
Housing Puller
Driver Attachment
Pilot, 26 x 30 mm
Clutch Spring Compresso. Attachmenr
SCS Service Connector
Backprobe Set
IVT Oil Pressure Hose, 2210 mmAy'T Oil Pressure Hose, Adapter
Ay'T Oil Pressure Gauge Set dpanelA,/T Low Pressure Gauge WpanelAdjustable Bearing Pulter, 25 - 40 mmAftachment, 62 x 68 mm
Aftachment, 72 x 75 mmDriver 40 mm l.D.
Driver
Driver Attachment, 68 mm
I
1
1
1
I
1,l
'l
1
I
1
1
14-133, 180
14-160, 163
14-135
14-171
14-'t7'l
14-160, 163
14-49
14-50, 113
r4-119
14- 1 19
14-119'14-1 19
14-172,173
14-172,'t73,114
14-172,174
14-153, 167. 169, 170
1+17 1 , 17 2, 173, 17
14-'t7'l
4
w
@o
*07HAE - P150101 can be used as a substitute.**Must be used with commercially-available 3/8,, _ 16 slide
E-E
@
@@
hammer.
=k
lalg
€)
ry
o
e
@
o
----a\\<-t-'- /\26
@@
@@@
aL
14-2

Description
The automatic transmission is a 3-element torque converter and a dual-shaft electronically controlled unit which provides
4 soeeds forward and 1 reverse.
Torque Convertel, Geats, and Clutches
The torque converter consists of a pump, turbine and stator, assembled in a single unit. They are connected to the engine
crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gear
which meshes with the starter pinion when the engine is being started. The entire torque converter assembly seryes as a
flywheel while transmiuing power to the transmission mainshaft.
The transmission has two parallel shafts: the mainshaft and the countershaft. The mainshaft is in Iine with the engine
crankshaft. The mainshaft includes the 1st, 2nd and 4th clutches, gears tor 2nd, 4th, reverse and lst (3rd gear is integral
with the mainshaft, while the reverse gear is integral with the 4th gear). The countershaft includes the 3rd clutch, and
gears for 3rd,2nd, 4th, reverse. 1st and park. The gears on the mainshaft are in constant mesh with those on the counter-
shaft. When certain combinations of gears in transmission are engaged by clutches. power is transmitted from the main-
shaft to the countershaft to provide E, ld, E, and E positions.
Electronic Control
The electronic control svstem consists of the Powertrain Control Module {PCM), sensors, a linear solenoid and four
solenojd valves. Shifting and lock-up are electronically controlled for comtonable driving under all conditions. The PCM is
located below the dashboard, under the front lower panel on the passenger's side
Hydraulic Control
The valve bodies include the main vatve body, the secondary valve body, the regulator valve body, the servo body and the
lock-up valve body through the respective separator plates, They are bolted on the torque converter housang
The main valve body contains the manual valve, the 1-2 shift valve. the 2nd orifice control valve, the CPB {Clutch Pressure
Back-up) valve, the modulator valve. the servo control valve, the relief valve, and ATF pump gears The secondary valve
body contains the 2-3 shift valve. the 3-4 shift valve, the 3-4 orifice control valve, the 4th exhaust valve and the CPC (Clutch
pressure Control) valve. The regulator valve body contains the pressure regulator valve, the torque converter check valve,
the cooler relief valve, and the lock-up control valve. The servo body contains the servo valve which is integrated with the
reverse shift fork, and the accumulators. The lock-up valve body contains the lock-up shift valve and the lock-up timing
valve. The linear solenoid and the shift control solenoid valve Ay'B are bolted on the outside of the transmission housing,
and the lock-up control solenoid valve Ay'B is bolted on the outside of the torque converter housing. Fluid from regulator
passes through the manual valve to the various control valves. The clutches receive fluid from their respective teed pipes
or internal hydraulic circuit.
Shift Control Mechanism
Input from various sensors located throughout the car determines which shift control solenoid valve the PCM will activate
Activating a shift control solenoid valve changes modulator pressure, causing a shift valve to move. This pressurizes a line
to one of the clutches, engaging that clutch and its corresponding gear, The shift control solenoid valves A and B are con-
trolled by the PCM.
Lock-up Mechanism
In ,Dt1 position, in 3rd and 4th. and in E position in 3rd, pressurized fluid is drained from the back of the torque converter
through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the
mainshaft rotates at the same as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing of
the lock-up mechanism. The lock-up valves control the range of lock-up according to lock-up control solenoid valves A and
B, and linear solenoid. When lock-up control solenoid valves A and B activate, the modulator pressure changes The lock-
up control solenoid valves A and B and the linear solenoid are controlled by the PCM.
(cont'd)
14-3