washer fluid HONDA CIVIC 1997 6.G User Guide

Lower Valve Body Assembly
Replacement
@ Make sure lifts, iacks, and saf€ty stands
are placsd prop€rly {sea section 1).
CAUTION: While removing and installing th6 lower
valve body asssmbly, b€ sule not to allow dust and
other for€ign particles to entsr inio the transmksion.
1. Raise the front of the vehicle, and support it with
safetv stands (see section 1).
2. Set the parking brake, and block both rear wheels
securetv.
4.
6.
Remove the drain plug, and drain the CVT fluid.
Reinstall the drain plug with a new sealing washer(see page 1+299).
CAUTION: Keop all of other toreign parliclos out of
the transmission.
Disconnect the 8P connector from the solenoid har-
ness connector.
Remove the ATF cooler hoses at the ATF cooler
lines. Turn the ends of the ATF cooler hoses up to
prevent ATF from flowing out, then plug the ATF
cooler noses.
CAUTION: Keep all of other foroign particlo3 out of
tho transmission.
Remove the right front mounvbracket.
10 x 1.25 mmila N.m (,1.5 kgf.m, 33 lbtft)
RIGHT FRONTMOUNT/BRACKET
ATF COOLER LINE
10 x 1.25 mmsil N.m 15.5 kgf.m,40 rbr.ft)
ATF COOLER HOSE
14-302
14.
7. Remove the ATF cooler outlet line.
8. Remove the ATF cooler line bracket bolt.
9. Remove the ATF pan (fourteen bolts).
10. Remove the ATF strainer (two bolts).
1 l. Remove the one bolt securing the solenoid harness
connector,
12. Remove the
bolts).
lower valve body assembly (eight
LINE BOLT28 N.m (2.9 kgtm,21 lbtft)SEALINGReplace.
ATF COOI.-EROUTLET
OOWEL PIN
O.RINGFeplace.
SOLENOIO HARNESSCONNECTOR
5x1.0mm12 N.m 11.2 kgt.m,8.7 tbt.ftlO.RINGReplace.ATFSTNAINER
6x1.0mm12 N.m 11.2 kgt m,E.7 tbt'ft)
OOWEL NN
BODY ASSEMBLY
6x1.0mm12 N.m 11.2 kgf.m,8.7 rbf.ft)
ATF PAN GASKETReplace.
VALVE
ATF COOLER INLETUNE BRACKET BOLT8 x 1,25 mm26 N.m {2.7 kgf.m,20 tbf.frl
13.
ATF PANx 1.0 mm12 N.m 11.2 kgf.m, E.7 lbf.ftl
Install the new lower valve bodv in the reverse
ordgr of the removal orocedure.
CAUTION: Koep all ot other fo.oign particles out of
ths transmission.
NOTE:
. Replace the following parts:
- O-rings on the solenoid harness connector
and the ATF strainer- ATF pan gasket- Sealing washers
. lf the ATF cooler inlet line bracket is bent or
warped, put it back to the original position.
Perform the start clutch calibration orocedure on
page 14-293.

ATF Filter
l.Removal/lnstallation
!@ Make sure lifts, lEcks, snd safoty stands
ara pl8ced properly {sae section 1).
CAUTION: While removing and installing the ATF tilier,
be sure not to allow dust or other for6ign particle3 to
enter thg transmission.
1. Raise the front of the vehicle, and support it with
safety stands (see section 1).
2. Set the parking brake, and block both rear wheels
securely.
3. Remove the drain plug, and drain the CVT fluid.
Reinstall the drain plug with a new sealing washer
{see page 14-299).
fl,
5.
CAUTION: Keep all toreign particles out ot the
transmission.
Remove the ATF cooler hoses at the ATF cooler
lines. Turn the ends of the ATF cooler hoses up to
prevent ATF from flowing out, then plug the ATF
cooler noses.
CAUTION: Keep all foreign particles out of the
transmission.
Remove the right front mounvbracket.
10 x 1.25 mm4{ N.m {i1.5 kgf.m,33 lbf ft)
ATF COOLER LINE
10 x 1.25 mm54 N.m {5.5 kgt'm,
40 rbl.ft)
ATF COOLER HOSE(|'t
14-303
6. Remove the ATF cooler outlet line.
7. Remove the ATF cooler line bracket bolt.
8. Remove the ATF pan (fourteen bolts)
9. Remove the ATF cooler inlet line from the ATF pan
(three bolts).
10. Remove the ATF filter, and clean it.
11. Check that the ATF filter is in good condition.
12. Replace the ATF filter if it is clogged.
LINE BOLT28 N.m {2.9 kgf.m,21 lbt.ft)
ATF COO1TR OUTIET
6x1.0mm
ATF COOLER INI-ETLINE ERACKET BOLT8 x 1.25 mm26 N.m (2.7 kgt.m,20 rbtftt
O.RINGReplace.
ATF
ATF FILTER
ATF PAN
6x1.0mm12 N.m (1.2 kgt'm,8.7 lbl'ft)
lnstall the ATF filter in the reverse order of the
removal procedure.
GAUTION: Keep all foreign particles out ot the
transmission,
NOTE:
Replace the O-rings, the ATF pan gasket and
sealing washers.
lf the ATF cooler inlet line bracket is bent or
warped. put it back to the original position
GASKETReplace.
'13.
12 N m (1.2 kgf m,

I
6. Disconnect the vehicle speed sensor (VSS) connec-
tor, the driven pulley speed sensor connector, and
the secondary gear shaft speed sensor connector.
SECONDARY GEARSHAFT SPEEDORIVEN PULLEY
SPEED SENSORCONNECTORSENSOR
7. Remove the transmission housing mounting bolts.
14-305
8. Remove the drain plug, and drain th€ CVT fluid
Reinstall the drain plug with a new sealing washer.
CAUTION: While installing the drain plug' bo 3ur.
nol io allow du3l 8nd other toreign particles to
enter into th€ trsnsmi$ion.
DRAIN PLUG18 x 1.5 rnm(, N.m (5.0 kgfm, 36 lbf'ft|
9. Remove the splash shield.
SEALING WASHERReplaco.

Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING

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

Steering Gearbox
Disassembly (cont'd)
8. Remove cylinder lines A and B from the gearbox.
CYLINDER LINE gCYLINOCR LINE A
Drain the fluid from the cylinder fittings by slowly
moving the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body unit from the gearbox. (See page 17-52 forvalve body unit disassembly.)
VALVE BOOY UNITFLANGE BOLT
10.
'96 - '97 mod.ls:32 mm SHIMS98 - '00 modok:WAVE WASHER
17-50
13. Loosen and remove the cvlinder end.
11. Drill a 3 mm (0.12 in) diameter hole approximatety
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the stakedpoint on the cylinder.
cAunoN:
o Do nol allow metal shavings to onter the cylin.
der housing.
. After romoying iha cylinder end, remova any
bur6 at the staksd point.
Dcpthi 2,5 - 3.0 mm {0.10 - 0.12 in}
CYUNDER
12. Hold the steering
snown.
gearbox using a C-clamp as

)Reassembly
NOTE:
. clean the disassembled parts wrth a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly'
. Apply the recommended power steering fluid to the parts+ndicated in the assembly procedures'
o Do not a||ow dust, dirt, or other foreign materials to enter the power steering system.
a Use the appropriate special tools where necessary'
FLANGE BOLTS20 N.m (2.0 kgt'm, 14lbf ftl
CYLINDER LINE B
VALVE HOUSINGFLARE NUTS
28 N.m (2.7 ksf m,20 lbf ftl
VALVE OIL SEAL
Replace.
CYLINDER END SEAL
Replace.
f itllTllli".",'r'o,.n,ft
''*^'*-1$*€-/s6-,,mode,3:
EUSHINGReplace 'P'\-- BEARING
SLEEVE SEAL RINGS ..-------...... SS
.----
",a"a,,
*---
--,
Replace. lss-, Replace.
Xll,Y5"l'.
"o. --r...- gY------..r.u,
,-f-..-S: _ ,96 _,9? models:
--€l€--------=- ircriip'ii.rt'-l./BACKUPReplace.
I,
wAvE wAsHER d
-.-.-r_ i"pru"".
CYLINDER HOUSING // -\-
, AJ - O.RING
/ ,S-'..- ReDtace.
_ j GEAR HouslNG l.g --'\-
\- t F
tonsrnrr
.,_- s
- 'oo ,,iod"t., -s-'--------- vALvE SEAL R'NG
S_.<---,tj- 97 models onlY:
CYLINDER END SEAL
)@OOD m n"prac".
/'\N,."._nrNG I '98 - 'oo - RACK GUIDE
models:
:scREw I
O.RINGReplace..98 - '00 models:
CYLINDER END69 N.m {?.0 kgt'm,51 lbl'ft)
(cont'd)
17-55
CYLINDER LINE A
tJ

Steering Gearbox
Reassembly (cont'd)
Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl taoe with
the power steering fluid.
2. Install the backup ring ('96 -'97 models) or wavewasher ('98 -'00 models) with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil sealwith power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being
careful not to damage the sealing lip.
Vinyl t.po{Stepped ponion}
Tap6red position.
BACKUPGroove side.
sure the spring isseatod in the oil seal.
'98 - '00 mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Apply vinyl tape to the splines and stepped portion
of the shaft, and coat the surface of the vinyl tapewith the power steering fluid.
Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaft
and the groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft,
'96 - '97 models:
lip
7.
VALVE SEAL RIiIGReplace.Do not over-expand.
17-56
8. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
9. Apply power steering fluid to the inside of the spe-cial tool. Set the larger diameter end of the specialtool over the valve seal ring.
10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.11, Remove the soecial tool.
12. Turn the special tool over, and set the smaller diam-eter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinion
shaft.
PISTON SEAL BINGSIZING TOOL07NAG - SR:togoAol07NAG - SR3|X)00
(g(m
Use the larger diameterend of the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe specialtool.

Front Brake Caliper
2056 Type:
@
Disassembly (cont'dl
Nevor u3e an air hos€ or dry brush to clgan brake
assomblios.
Use an OSHA approved vacuum cl6aner to avoid
braathing braks duet.
CAUTION:
. Do not spill brakefluid on ths vchicle; it may damage
the paint; if brako fluid does contact the p.int. wash
it olt immediately with wato..
. To prevsnt spills, cover the ho3o ioints whh rag3 or
shop towels.
. Cl€an all parts in brake fluid and air dry; blow out 8ll
passagss with compr63€d air.
1. Remove the banjo bolt, and disconnect the brake
hose from the caliper.
SEALING WASHERS
Remove caliper bolt B, pivot the caliper up out of
the way, then remove the caliper from the bracket.
Remove the guide pin boot from sleeve A on the
caliDer bracket.
GUIDE PIN BOOTReplace.
GALIPER BRACKETCheck tor cracks.
Check for damage.
19-14
4. Remove the pin boot, sleeve B and sleeve boot
from the caliper body.
CALIPER EODYCheck for scoringon cytinder wa .
SLEEV€ BCheck for damage.
lf necessary, apply compressed air to the csliper
fluid inlet to get the piston out. Place a shop rag or
wooden block as shown to cushion the oiston when
it is expelled. Use low pressure air in short spurts,
a
a
Do not placo your lingers in ftont ol tho pkton.
Do noi usa high air prsssure; uso an OSHA
approved 30 PSI nozzle.
Remove the piston from the caliper, and check thepiston for scoring.
WOODEN ALOCK

'1.Clean the piston and caliper bore with brake fluid,
and inspect for wear and damage.
Coat the new piston seal with the recommended
rubber grease in the caliper seal set. and install the
seal in the cylinder groove.
Apply the recommended seal grease in the caliper
seal set to the sealing lips and inside of a new pis-
ton boot, and securely install it in the caliper with the
new boot clip.
CAUTION: Be careful nol to damage the caliper
cylinder wall.
PISTON SEALReplace.
--^.,:=-qE!!!-HRUBBER GREASE
Lubricate the caliper and piston with brake fluid,
then install the piston in the cylinder with the dished
end facing in.
IJPISYON BOOTReplace.
j@i
SILICONE GREASE
CALIPER
-6lCALIPEB PIN B
Apply the recommended seal grease in the caliper
seal set to the sliding surface of the pins and the
lnside of the new pin boots.
lnstall the pin boots into the grooves in the caliper
bracket properly.CALIPER ERACKET
7. Insert pin A and pin B into the caliper bracket.
8. Install the pin boots into the grooves in the pans
propeny.
9. Install the brake pads in their original positions (see
page 19-9).
10. Push in the piston so that the caliper will fit over the
pads, and install the caliPer.
11. Tighten the caliper bolts.
12. Connect the brake hose to the caliper with new seal-
ing washers, and tighten the banjo bolt.
-6.lPIN BOOTSReplace.
-6lCALIPER PIN
BANJO EOLT34 N.m (3.5 kg{ m, 25 lbflt}SEALING WASHERSReplace.
'13.
CALIPER BOLT32 N.m 13.3 kgt.rn, 24lblft)
Fill the brake reservoit and bleed the brake system
{see page 19-7).
Perform the following checks:
. Check for leaks at hose and line joints and con-
nections. and retighten if necessary.
. Check for brake hoses for interference and twisting.(cont'd)
14.
19-17