air HONDA CIVIC 1997 6.G Workshop Manual

CAUTION: lf eithd end of the 3pocial tool issotoveran
area ot the spring rstainer which is unsupport€d by tho
return spring, tho r€tain€l may be damagod. Bo eure the
special tool is adiusted to have full contact with tha
spring retainor.
SPRING RETAINER
4. Compfess the return sprang.
Do not sat horo.
5. Remove the snap ring. Then remove the special tools,
spring retainer and return spring.
Wrap a shop rag around the clutch drum, and apply
air pressure to the ATF passage to remove the pis-
ron.
Place a finger tip on the other end while applying
air pressure.
OSHA.APPROVED
SPRING RETAIItIER
PISTON
14-161

Clutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
a
cleaner, and dry them with compressed air.
Blow out all passages.
Lubricate all parts with ATF before reassembly.
Inspect the check valve; if it's loose, replace the pis-
to n.
1.
CHECK VALVE
2. Install new O-rings on the clutch piston.
O RINGS
PISTON
-
14-162
3. Install the piston in the clutch drum, Apply pressure
and rotate to ensure proper seating,
NOTE: Lubricate the piston O-ring with ATF beforeinstalling.
CAUTION: Do not pinch the O-ring by insta ing thepiston with too much force.
CLUTCII DRUM
Install the return spring and spring retainer, andposition the snap ring on the retainer.
CLUTCI{ DRUM

16. Install a new set ring on the end of each driveshaft'
17. Installthe right and left driveshafts (see ssction 16)
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor for-
eign particl€s to enler into the transmission.
NOTE:
. Clean the areas where the driveshafts contact the
transmission (differential) thoroughly with sol-
vent or carburetor cleaner, and dry with com-
pressed air.
. Turn the right and left steering knuckle fully out-
ward, and slide each driveshaft into the differen-
tial until you feel its set ring clip engage the side
gear.
18. Install the damper fork, then install the rightand left
ball joints to the each lower arm with the castle nuts
and new cotter Plns.
DAMPER PINCH BOLT
10 x 1 .25 mma3 N.m l4.ia kgf.m,
32 tbl.ftl
4l
COTTERReplace.SELF.LOCKING NUT
12 x 1.25 mm
6il N.m t6.5 kgf'm, il7 lbf ftl
Replace.
19. Install the splash shield.
{5.0 - 6.0 kgf m, 36 - iB lbf'ft|
CASTLE NUT12 x 1,25 mm49 - 59 N.m
20. Connect the mainshaft speed sensor, the linear sole-
noid and the shift control solenoid connectors.
SHIFT CONTROL SOLENOIO LINEAR SOITNO|o
CONNECTOR CONNECTOR
6 r 1.0 mrn12 N.m (1.219f.m,
E.7 lbf.frl
CONNECTOR
21. Connect the countershaft speed sensor and the vehi-
cle speed sensor (VSS) connectors.
VEHICI..E SPEED
SENSOR CONNECTOR
COUNTERSHAFTSPEED SENSORCONNECTOR
(cont'dl
14-185

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.

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

Troubleshooting Procedures
l. How To Begin Troubleshooting
When the E indicator light has been reported on, use the appropriate procedure below to diagnose and repatr theproDlem.
A. When the @ indicator light has come on:
l connect the Honda PGM Tester or an oBD ll Scan Tool to the 16P Data Link Connector (DLc) located near the leftkick panel.
Turn the ignition switch ON (ll).
Check the DTC and note it. Also check and notethe freeze frame data.
Refer to the Diagnostic Trouble Code Chart andbegin troubleshooting.
INOICATORLIGHT
NOTE: SeetheOBDll Scan Tool or Honda PGM Tester user's manuals for specific operating instructions.
Some PGM-FI problems will also make the E indicator light come on. After repairing the pGM-Fl system, disconnect theBACK UP fuse (7.5 Al in the under-hood fuse/relay box for more than l0 seconds to reset the TCM or PCM memory, rnenrecheck.
NOTE: Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting. Make note of theradio presets before removing the fuse so you can reset them,
2.
3.
o0\e--loo
OATA LINK CONNECTOB I16P}
14-234

B. DTCS will be indicated by the blinking of the E indicator light with the SCS service connector connected to the
Service Check Connector as shown. (The Service Check Connector (2P) is located under the dash on the passen
ger's side of the vehicle.) Turn the ignition switch ON (ll).
CONNECTOR07PAZ - 00101(x)
codes 1 through 9 are indicated by individual shon btinks. codes 10 and above are indicated by a series of long and short
b|inks.one|ongblinkequa|sloshortb|inks.Addthe|ongandshortb|inkstogethertodeterminethecode.Afterdeter
miningthecode,refertothee|ectrica|systemsymptom-to-componentchartonpagesl4-238and14.239forthe,96_98
models, and on pages 14-240 and 14'241 for the '99 - 00 models
Soc DTCI
Sor DTC2
Long blinkShort blinks |tive tim€sl
some pGM-Ft problems wi

atso make the E indicator light come on. After repairing the PGM-FI system, disconnect the
BACKUPfuse(7.5A)intheUnder.hoodfuse/re|ayboxformorethanl0secondstoresettheTcMorPcMmemory,then
recheck.
Scc DTCI5
(cont'd)
14-235
iii:j
,,,/
CONNECTOR {2PI
Shorl blink (oncc)

lf the self-diagnostic E indicator light does not blink, perform an inspection according to the table below.
SymptomInspectionRef. page
E indicator light does not come on for two seconds after ignition switch
is first turn on (ll).14-262
E indicator light is on constantly (not blinking) whenever the ignition
switch is on (ll).14-264
NOTE:
. lf a customer described the symptom for code P1706 (6), it will be necessary to recreate the symptom by test driving,
then recheck the DTC.
. Sometime the E indicator light and the Malfunction Indicator lamp (MlL) may come on simultaneously. lf so, repair the
pGM-Fl system according to the DTc, then reset the memory by removing the BACK uP fuse in the under-hood
fuse/relay box for more than 10 seconds. Drive the vehicle for several minutes at a speed over 30 mph (50 km/h)' then
recheck the DTC.
14-239

lf the self-diagnostic E indicator light does not blink. perform an inspection according to the table below.
SYmPtom
IDI indicator light does not come on for two seconds after ignition switch
is first turned ON (ll).
lE1 indicator light is on constantly (not blinking) whenever the ignition
switch is ON { ll).
InspectionRef. page
14-284
14-290
NOTE:
. lf a customer described the symptom for code Pl706 (6), it will be necessary to recreate the symptom by test driving,
then recheck the DTC.
. iometimes, tfre E indicator light and the Malfunction Indicator lamp (MlL) may come on simultaneously lf so, repair
the PGM-Fl system accordrng to the DTC, then reset the memory by removing the BACK UP RADIO fuse in the under-
hood fuse/relay box for more than 10 seconds. Drive the car for several minutes at a speed over 30 mph {50 km/h)' then
recheck the DTC.
14-241