hose HONDA CIVIC 1996 6.G Manual Online

Electrical Troubleshooting ('96 - 9g Models)
Troubleshooting Flowchart - A/T Gear position Switch (Shortl
NOTE: Record allfreeze data before you troubleshoot.
Poiriblo Caus6
. Short in A/T go.. positionawhch wira. Fauhy A/T goa. position swhch
NOTE: Code P1705 (5)the PCM receives twoinputs at the same time.
is caused whengear position
' OBD ll Scln Toot indic.tes Cod6P1705.. Sofidi.gno3b E indicato] tighrblinksfivatim...
Observo th. A/T Go.r po3ition
Indicator:1. Turn the ignition switch ON l).2. Observe the A"/T gear positionindicator, and shitt to eachposttron,
Do any indicatoG stay onwhen the shift lever is not inthose positions?
Tho sy3tem b OK.t this timo.Check th6 wilc harnari for dam-rga.
M.r.ur. ATP R Vohlge:1. Shift to all positions otherthanE.2. Nileasure the voltage betweenthe 816 and Ag or A22 tormi-nats,
Check for short in tha wirobstwacn the 816 tcrminal and th6A/T go.r porition rwitch or A/Tg..r position indicltor. It wira i3OK, ch.ck for loo!€ FCfit connoc-to13. lf nacetaary, subrtitute aknown€ood Pcllt and roa|rsck.
ls there battery voltage?
Meesur. ATP NP Vohage:1. Shift to allpositions oth€r thanEorE.2. Moasure the voltage betweenthe 825 and A9 or A22 terminats.Check for short in the wireb.tw..n th6 B:I5 torminrt and th.A/T gclr poahion indicator. o. .short in tha wirrs between th.A/T gclr position indicator rndthe A/T gerr poiition switch. lfwir.3 r.o OK, chack tor loosoPCM conn.ctorr. It n.cosarry.sub.tituto a known-good pCM.nd r.chock.M.Gur. ATP D4 Voltago:1. Shift to allpositions otherthanlD.l.2. Measure the voltage betw€enrhe 824 and Ag or A22 termi-nals.
Check tor 3hort in tho wirobc{wocn the 824 terminrl and thoA/T ge.r poiition switch. lI wileia OK, chock tor loo3o plCM con-ncctoaa. It nacossarv, sublthute aknown-good PCM and rech€ck.
ls there approx. 5 V?
PCM CONNECTORS
Wire side of female terminals
YES
To page 14-6':
14-60

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
Removal(cont'd)
'10. Remove the cotter pins and castle nuts, th€n separatethe balljoints from the lower arms (see section 1gl.
DAMPER PINCH BOLT
NUT
FORI(FORK BOLT
11. Remove the right damper fork bolt. th€nright damper fork and dampor.
COTTER PINReplace.
separate
12.
1a
14.
Pry the right and left driveshafts out ofthe differential.
Pull on the inboard joint to remove the right and leftdrivsshafts (see section 16).
Tie plastic bags over the driveshaft onds.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A,
NOTE: Dl6YB engine is shown; D16y7 engine issimilar.
t9.
SELF-LOCKING NUTReplace.
L
14-124
EXHAUST PIPE AMOUNT/BRACKET
17.
18.
16. Remove the shift cable cover. then remove the shiftcable by removing the control lever,
CAUTION: Take car6 not to bond the shift cable.
Remove the right front mounvbracket.
Remove the ATF cooler hoses at the ATF coolerlines. Tufn the ends of the ATF cooler hoses uo toprevent ATF from flowing out, then plug the ATFcooler hosgs and lines.
NOTE: Check for any sign of leakage at the hoseioints.
WASHER

Transmission
Installation (cont'dl
9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque. then to thefinal torque, in a crisscross pattern.
After tightening the last bolt, check that the crank-shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6x1.0mm12 N.m (1.2 kgt m,8.7 rbt ft)
I 1.25 mm2/t N.m {2.4 kg{.m,17 tbt ftlCONVERTEB
10. Install the torque convener cover and the €nginestiffener.'11. Tighten the crsnkshaft pull€y bolt, if necessary (see
section 61.
12. Connect the ATF cooler hoses to the ATF cooler lines(see page 1,t192).
ATF COOIIRUNE
10 x 1.25 mma,l N.m {4.5 kgl.m,33 rbt.fttRIGHT FRONT 12 x 1.25 mmMOUNT/BRACKET 6.t N.m (6.5 kg{.m,47 tbt ftl
13. Install the right front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Install the control lever with a new lock washer tothe control shaft, then install the shift cable cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHERReplace.
8 x 1,25 r'|m22N-m12.2 tgt m. 16lbnftl
x 1.0 mmtit N.m 11.4 kgt m,10 tbr,ft,
15. lnstall the exhaust pipe A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_ilar.
Replace.
GASKETReplace.
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 lgf.m,40 tbt ftl
NUTSELF.LOCKING NUTReplace.8 x 1.25 mm22 N.m {2.2 kgl.m, 16lbtfrl
Replace.8 x 1.25 mm16 N.m {1.6 kgI.m,12 tbf.ft)

Cooler Flushing
!!!@ To prevent iniury to. face and eyas, always
-ea. safetv glasses ot a face shield when using the
transmission flusher.
NOTE: This procedure should be performed before rein-
stalling the transmission.
1. Check the tool and hoses for wear and cracks before
using. lf wear or cracks are found, replace the hoses
before using.
Using the measuring cup, fill the tank with 2'l ounces
(approximately 2/3 full) of biodegradable flushing
fluid (J35944 - 20). Do not substitute with any other
fluid. Follow the handling procedure on the fluid
contarner.
Secure the flusher filler cap, and pressurize the tank
with compressed air to between 550 - 829 kpa (5 6 -
8.45 kgflcm'. 80 - 120Psi).
NOTE: The air line should be equipped with a water
trap to ensure a dry air system.
Hang the tool under the vehicle.
Attach the tank's discharge hose to the return line
of the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-
mission cooler using a clamP
IMPORTANT:
Securely clamp the opposite end oJ the drain hose to a
bucket or floor drain.
TRAMtssroN
TRANSMISSION COOLERFLUSHER{Commcrci.llY avail.blel
Kent-Moore J384O5'Aor equivelent
NS
I
{r Water
7. With the water and air valves off, attach the water and
air suDolies to the flusher' lHot water if available.)
8, Turn on the flusher water valve so water will flow
through the cooler for 10 seconds.
NOTE; lf water does not tlow through the cooler, it
is completely plugged. cannot be flushed, and must
be replaced.
9. Depress the trigger to mix the flushing fluid into the
water flow. Use the wire clip to hold the trigger down'
While flushing with the water and flushing fluid for
two minutes, turn the air valve on for five seconds
everv 15 - 20 seconds to create a surging action'
AIR PRESSURE: MAX 845 kpa {8.45 kgf/cm', 120 psi)
Turn the water valve off. Release the trigger, then
reverse the hoses to the cooler so you can flush in
the opposite direction. Repeat steps 8 through 10'
12, Release the trigger, and rinse the cooler with water
onlv for one minute
13. Turn the water valve off, and turn off the water supply
14. Turn the air valve on to dry the system out with air
for two full minutes or until no moisture is visible
leaving the drain hose.
CAUTION: Residual mobturo in tho cooler or pipas
can damage the transmksion'
15. Remove the flusher from the cooler line. Attach the
drain hose to a contalner.
16. Install the transmission, and leave the drain hose
attached to the cooler line
{cont'd)
10.
'11.
14-187

Transmission
17.
Cooler Flushing (cont'dl
Make sure the transmission is in the E position.
Fill the transmission with ATF, and run the enginefor 30 seconds or until approximately 0.95 f (1.0 USqt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the coolerreturn hose to the transmission (see page l4-192).
Refill the transmission with ATF to the oroDer level(see page 14-118).
18.
19.
b
14-18A
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with waterand pressurize the can. Flush the discharge line toensure that the unit is clean.
2. lf discharge liquid does not foam, the orifice may beblocked.
3. To clean, disconnect the plumbing from the tank atthe large coupling nut.
ORIFICE
GRT{G
Remove the in-line filter from the discharge side andclean if necessary.
The fluid orifice is tocated behind the filter.Clean it with the pick stored in the bottom of thetank handle, or blow it clean with air. Securelvreassemble all Darts.
FILLER CAP

Shift Indicator PanelATF Cooler Hoses
Adiustment
'1.Check that the index mark on the indicator alionswith the N mark on the shift indicator panel whenthe transmission is in NEUTRAL.
3 N.m {0.3 kgf.m, 2lbt.ftl
lf not aligned. remove the front console {see section20t.
Remove the shift indicator panel mounting screwsand adjust by moving the panel,
NOTE: Whenever the shift indicator panel is removed,reinstallthe panel as described above,
INDEX MARK
L
14-192
Connection
1. Connect the ATF cooler hoses to the ATF cooler linesand ATF cooler, and secure them with the clips asshown.
TRANSMISSION CLIP

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

Special Tools
Ref. No. I Tool Number
o
@alr *
@
o
@6l
@
o
@
@-"
@
@
@
o
@
07GAE - PG40200
07JAD - PH80200
07LAE - PX40100
07PM - 0010100
07sM- 0010004
07TAE - P4V01l0
07TAE - P4V0120
07TAE - P4V0130
07 tvlAJ - PY4011A
07MAJ - PY40l20
07406 - 0020400
07406 - 0070300
07736 - A0r 0004
07746 - 0010100
07746 - 0010500
07746 - 0010600
07746 - 0030100
07749 - 0010000
07947 - 6110501
01947 - 6340201
Clutch Spring Compressor Bolt AssemblyPilot. 26 x 30 mm
Clutch Spring Compressor Attachment
SCS Service Connector
Backprobe Set
Reverse Brake Spring Compressor
Stan Clutch Remover
Stan Clutch Installer
A/T Oil Pressure Hose,2210 mmAy'T Oil Pressure Hose, Adapter
Ay'T Oil Pressure cauge Set WpanelAy'T Low Pressure Gauge w/panel
Adjustable Bearing Puller, 25 - 40 mmAttachment, 32 x 35 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Driver 40 mm l.D.
Driver
Driver Aftachment, 68 mm
Driver Attachment, 58 x 72 mm
I
1
2
Ia,l
1
1
1,1
1
1'1
I
1
1
't4-322,325
14-333
14-322,325't4-235,293
14-236, 296
r4-319,339't 4-311
14-342,343't4-300
14-300
14-300
14-300
14-335
14-333, 336
14-335
14-334, 335
14-330, 331
14-333, 334, 335,
336
14-333
14-333*07HAE - PL5010l can be used as a substitute.**Must be used with commercially-available 3/8.,- 16 slide hammer.
E*E
o
e
@
>.'.- -t-'- t'\;4
e'o
1:,'Jt*
dAt:-
io(313
@
@
@
@18l
aio
@
IR
L
14-194

E Position
Astheengineturns.theATFpumpa|sostartstooperate.F|uidfromtheATFpumpf|owstothePHregu|atorva|veandthe
c|Utchreducingva|ve.ThePHregu|atorva|veregu|ateshighpressure(PH).andsendittotheshiftVa|veandthePLregU'
latorvalve.Thehighpressure(PH)flowstothemovablefaceofthedrivenpulleyviatheshiftvalve'andturnsintolow
pressure(PL)atthePLregu|atorva|ve.Thelowpressure(PL}f|owstothemovab|e'aceofthedrivepu||eYviatheshift
valve. At this time, the pulley ratio remarns low'
Thehighpressure(px)uecomesttrectutchreducingpressure(CR)atthec|utchreducingva|Ve.Thec|utchreducingpres.
sure (CR) flows to the start clutch cont'oi uatt". tn"lt"n'al valve' the PH-PL control valve' and the shift control valve' and
is intercepted bY those valves
Under this condition, hydraulac pressure is not applied to the clutches and reverse brake'
(cont'd)
14-213