Clutch adjustment HONDA CIVIC 1996 6.G Workshop Manual

Probable Cause List lFor th€ DTC Chart, see page 11-971*: '99 - 00 models
Probable GausePageSystem
11 1-107Engine Control Module (ECM)/Powertrain Control Module (l'uM)
PGM-Fl main relay
l^^iti^n cwetam
211-230,231
3't't-237
Section 23
51'1-172,183Crankshaft Position/fop Dead Center/Cylinder Fosltlon sensor clrculr' Lr\F selrsor
circuit
Intake Air Temperature (lAT) sensor circuit
ldle Air Control (lAC) Valve
ldle speed adjustment
Throttle bodY
Throftle cable
Manifold Absolute Pressure (MAP) sensor
Throftle Position (TP) sensor
Barometric pressure (BARO) senso'
Mf g"a, po"ition signal (see page 11-216) or clutch switch signal
Brake switch signal
Air Cleaner
lntake air pipe
Three Way Catalytic Converter (TWC)
Evaporative emission (EVAP) control
Contaminated fuel
ORVR vent shut valvs
't1-124
71 1-194
I11-220 - 223
11-241
'1011-244
1111-115
1211-132
13't1-178
14Section 14. 11-218
1511-210
16't1-244
1811-252
1911-261
20
21*11-296
(cont'd)
11-85

J
t
Clutch
Speciaf Tools .......... ...........12-2
f lfustrated Index .......... ......12-3
clutch Pedal
Adjustment .................... 12'4
Clutch Master Cylinder
Removal/lnstallation ..... 12-5
Slave Cylinder
Removal/lnstallation .....12'6
Pressure Plate
Removal/lnspection ...... 12-7
Clutch Disc
Removal/lnspection ...... 12-8
Flywheel
Inspection ....................... 12-9
Replacement ....................................... 12-9
Clutch Disc, Pressure Plate
lnstallation ..................... 12-10
Release Bearing
Removal/lnspection ......12-11
f nstalfation .................,... 12-12
\

Glutch Pedal
Adjustment
NOTE:
. To check the clutch interlock switch and clutch
switch, see section 23.
. The clutch is self-adjusting to compensate for wear.
CAUTION: lf there is no clearance between the mas-
ter cylinder pislon and push rod, the release bearing
is held against the diaphragm spring, which can
result in clutch slippage 01 other clutch problems.
1. Loosen locknut A, and back off the clutch switch (or
adjusting bolt) until it no longer touches the clutch
peoar.
2. Loosen locknut C, and turn the push rod in or out to
get the specified stroke {@} and height (@) at tne
clutch pedal.
3. Tighten locknut C.
4. Thread in the clutch switch {or adiusting bolt) until
it contacts the clutch pedal.
9002)
Turn the clutch switch (or adjusting bolt) in an addi-
tional 3/4 to 1 full turn.
Tighten locknut A.
Loosen locknut B on the clutch interlock switch.
Measure the clearance between the floor board and
clutch pedal with the clutch pedal fully depressed.
Release the clutch pedal 15 - 20 mm {0.59 - 0.79 in)
from the fully depressed position and hold it there.
Adjust the position of the clutch interlock switch so
that the engine will start with the clutch pedal in
this position.
Thread the clutch interlock switch an additional in
3/4 to 1 full turn.
Tighten locknut B.
LOCKNUT B9.8 N.m (1.0 k91.m,7.2 lbt.tt)
INTERLOCK SWITCI{
J
'lL
5.
7.
8.
9.
10.
ASSIST SPRING
-Atl
CLUTCH SWITCH
lo. ADJUSTING BOLTI
LOCKNUT A9.8 N'm (1.0 kgI.m, 7.2 lbf,ft)
LOCKNUT C18 N.m {1.8 kql.m, 13lbf.ft}
@ (STROKE at PEDAL): 130 - 140 mm (5.12 - 5.51 in)
@ (TOTAL CLUTCH PEDAL FREE PTAYI: 12 - 21 mm (0.47 - 0.83 in) includethepedal play 1 10 mm (0.04 - 0.39 in)
@ (CLUTCH PEDAL HEIGHT): ']65 mm {6.50 in) to the floor
@ (CLUTCH PEDAL DISENGAGEMENT HEIGHT): 83 mm (3.27 in) minimum to the floor
12-4

Differential
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bot-toms in the clutch housing, using the special tool asshown.
DRIVER, 40 mm LD.07746 0030100
Install the thrust shim.
NOTE: Install the same size thrust shim that wasremoved.
Y
Install the transmission housing (see page l3-41).
NOTE: Do not apply liquid gasket to the mating sur-face of the clutch housing.
Tighten the transmission housing attaching bolts(see page 13-42).
I x 1,25 mm
27 N.m (2.8 kgt'm, 20 lbf'ft}
Use the special tool to bottom the differential assem-
bly in the clutch housing.
tJ
6. Measure clearance between thrust shim
ing outer race in transmission housing.
and bear-
13-32

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

Differential
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bot
toms in the clutch housing, using the special tool as
shown.
ORIVER, 40 mm LO.o7746-0030100
lnstall the 80 mm shim.
NOTE: lnstall the 80 mm shim that was removed.
mm SHIM
13-84
(
4.
Install the transmission housing (see page 13-94).
NOTE: Do not apply liquid gasket to the mating sur-
face of the clutch housing.
Tighten the transmission housing attaching bolts(see page 13-94).
I x 1.25 mm
27 N'm (2.8 kgf.m, 20 lbf.ftl
Use the special tool to bottom the differential assem.
bly in the clutch housing.
Measure clearance between the 80 mm shim and
bearing outer race in the transmission housing.

Mainshaft Thrust Clearance
Adjustment
1. Remove the 72 mm thrust shim and oil guide platefrom the transmission housing.
4.
TFANSMISSIONHOUSING
72 mm THRUST SH|M
TRAt{SMtSStONHOUSINGOIL GUIOE PLATE
lnstall the 3rd/4th synchro hub. spacer collar,5thsynchro hub. spacer, and ball bearing on the main_shaft, then install the above assembly in the trans_mission housing.
lnstall the washe[ on the mainshaft,
Measure distance @ between the end of the trans-mission housing and washer.
NOTE;
. Use a straight edge and vernier caliper.. Measure at three locations and average the read_ing.ENO otlnA sMtsstoNHOUSINGMAINSHAFT
3RD/irTH SYNCHRO HUB
SPACCR COLLAR
5TH SYNCHRO HUB
o
B
13-88
AALL BEARING
V.
5. Measure distance @ between the end of the clutchhousing and bearing inner race.
NOTE;
. Use a straight edge and depth gauge.. Measure at three locations and average the read-ings.
Select the prcpet 72 mm thrust shim from the chartby using the formula below.
NOTE: Us€ only one 72 mm thrust sntm.
Shim Selection Formula:
From the measurements you made in steps 4 and 5:. Add distance O lstep 5) to distance @ (step 4).
. From this number, subtract 0.93 (which is themidpoint of the flex range of the clutch housingbearing spring washer).
. Take this number and compare it to the availableshim sizes in the chart.
{For example)
B;2.39
+ C: 0.22- 0.93
2.61 = 1.68
Try the 1.68 mm (0.0661 in) shim.
INNER RACE ot EALL BEARING

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

PGM Terminal Voltage/Measuring Conditions ('99 - 00 Modelsl
A/T Control System
The PCM terminal voltage and measuring conditions are shown for the connector terminals that are related to the A/T con-trol system. The other PCM terminal voltage and measuring conditions are described in section 11.
PICM Connoctor Terminrl Location3
Terminal NumberSignalDescriplionMeasuring Condhions/Torminal Voltage
A7ATP DA,/T gear position switch
E position input
InEposition:OV
In other than E] position: Approx. 1O V
A9ATP NPA/T gear position switch
@ and S positions input
In E and El positions: 0 V
In other than E] and E position: Approx. 1O V
A10Timing and adjustment service
check signal
With ignition switch ON {ll} and service check
connector oDen: 5 V
With ignition switch ON (ll) and service check
connector connected with soecialtool:0 v
ATP LA,/T gear position switch
I position input
In E position; OV
In other than E position: Approx. 10 V
STOP SWBrake switch signal outputBrake pedal depressed: Battery voltage
Brake pedal released: 0 V
PCM CONNECTOR B I25P}
Terminal NumberSignalDescriptionMoasuring Condhions/Terminal Vohage
B1IGPlPower supply circuit from main
relay
With ignition switch ON (lll: Battery voltage
With ignition switch OFF: 0 V
82PG1Ground
B8HLC LSMPH-PL control linear solenoidpower supply neqative electrode
B9IGP2Power supply circuit from main
relay
With ignition switch ON (lll: Battery voltage
With ignition switch OFF:0 V
810PG2Ground
817HLC LSPPH-PL control linear solenoid
power supplypositive electrode
With ignition switch ON {ll): Pulsing signal
818SC LSMStart clutch control linear
solenoid power supply negative
electrode
s20LGIGround
821VBUBack-up power supplyAlways battery voltage
B22Ground
825SC LSPStan clutch control linear
solenoid power supply positive
electrode
With ignition switch ON (ll): Pulsing signal
t
14-232

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351