internal HONDA CIVIC 1998 6.G User Guide

Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When
hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse
brake piston move. This presses the friction djscs and the steel plates together, locking them so they don't slip. Power is
then transmitted through the engaged clutch pack to its hub-mounted gear. and through engaged ring gear to pinion
gears.
Likewise, when the hydraulic pressure is bled from the clutch pack and the reverse brake piston cavity, the piston releases
the friction discs and the steel plates, and they are free to slide past each. This allows the gear to spin independently on its
shaft, transmitting no power.
Start Clutch
The start clutch, which is located at the end of the driven pulley shaft, engages/disengages the secondary drive gear.
The start clutch is supplied hydraulic pressure by its ATF feed pipes within the driven pulley shaft.
Forward Clutch
The forward clutch, which is located at the end of the drive pulley shaft, engages/disengages the sun gear.
The forward clutch is supplied hydraulic pressure by its ATF feed pipe within the drive pulley shaft.
Reverse Brake
The reverse brake, which is located inside the inte.mediate housing around the ring gear, locks the ring gear in E posi-
tion. The reverse brake discs are mounted to the ring gear and the reverse brake plates are mounted to the intermediate
housing. The reverse brake is supplied hydraulic pressure by a circuit connected to the internal hydraulic circuit.
Planetary Gear
The planetary gear consists of a sun gear, a carrier assembly, and a ring gear. The sun gear is connected to the input shaft
with splines. The pinion gears are mounted to the carrier which is mounted to the fo.ward clutch drum. The sun gear
inputs the engine power via the input shaft to the planetary gear, and the carrier outputs the engine power. The ring gear
is only used for switching the rotation direction of the pullev shafts,
In E. E, and E positions (forward range), the pinion gears don't rotate and revolve with the sun gear, so the carrier
rotates. In E] positjon {reverse range), the reverse brake locks the ring gear and the sun gear drives the pinion gears to
rotate. The pinion gears rotate and revolve in the opposite direction from the rotation direction of the sun gear, and the
carrier rotates with pinion gear revolution.
Pulleys
Each pulley consists of a movable face and a fixed face, and the effective pulley .atio changes with engine speed. The
drive pulley and the driven pulley are linked by the steel belt.
To achieve a low pulley ratio, high hydraulic pressure works on the movable face of the driven pulley and reduces the
effective diameter of the drive pulley. and a lower hydraulic pressure works on the movable face of the drive pulley to
eliminate the steel belt slippage. To achieve a high pulley ratio, high hydraulic pressure works on the movable face of the
drive pulley and reduces the eifective diameter of the driven pulley, and a lower hydraulic pressure works on the movable
face of the driven pulley to eliminate the steel belt slippage.
b
14-198

Disassembly
Press the intermediate shaft out of the shaft bearing
using the special tools and a press as shown.
Remove the internal circliP
Press
I
SUPPORT BASEATTACHMENT07JAF - SH20400INTERNAL CIBCLIP
BEARING SUPPORT RING
Check for damage or distortion
6. Press the intermediate shaft bearing out ot the bear-
ing support using the special tools and a press as
shown.
HANOLE DRIVER
0?749 - 00'10000
Press
I
DRIVER ATTACHMENT,12x47 mm07746 - 0010300FLOATING RUBBEB
DAMPERCheck for deterioration
and oamage.SUPPORT BASE
ATTACHMENT07JAF _ SH20it00
BEARING SUPPORT
Check for damage
I sErR'NG
A4 Reolace
VUOUTER SEALReplace.(cont'd)
ReassemblY
NOTE:
. clean the disassembted parts with solvent, and dry them thoroughly with compressed air' Do not wash the rubber
parts with solvent.
. Becareful not to da mage the metal ringson the intermediate shaftduring reassembly'
BEARING SUPPORT RINGDOWEL BOLTS10 x 1.25 mm39 N.m 14.0 kgf.m,29 lbIftl
EXTERNAL CIRCLIP
Pack the interiorof the outer seal.2.0-35s10.07-012oz)
INTERNAL CIRCLIP
INTERMEDTATE SHAFT BEARING
Replace,
INTERMEDIATE SHAFT RING
lJ
16-21

lntermediate Shaft
Reassembly (cont'd)
1. Press the intermediate shaft bearing into the bear-ing support using the special tools and a press asshown.
Prass
I
DRIVER ATTACHMENT,52x55mm07746 - 001 0(X)
Seat the internal circlip in the groove of the bearingsuppon.
Press the intermediate shaft into the shaft bearingusing the special tools and a press.
Praa.r
I
@---
LJ
INTERMEDIATE SHAFT
DRIVER ATTACHMENT,35 mm LD.
16-22
Seat the external circlip in the groove of the inter-mediate shaft.
Install the outer seal into the bearing support usingthe special tools as shown.
NOTE: Install the seal ftush with the bearing sup-port.
Pre$
t HANDr.r DRTVER- 0011r(x)0
Pack the Interiorof the ouler seal.2.0- 3.5 g {0.07 -0.12 ozl
OUTEN SEAL
Install the new set ringgroove.
ORIVER ATTACHMENT,52x55mm077i16 - 0010/O0
in the intermediate shaft

)
Steering Pump
Construction
The pump is a vane-type incorporating a flow control valve (with an integrated relief valve) and is driven by a POLY-V-belt
from the crank pulley. The pump features 10 vanes. Each vane performs two intake/discharge operations for every rota-
tion of the rotor. This means that the hydraulic fluid pressure pulse becomes extremely small during discharge.
/
ROTORVANE CAM RING
Operation
The belt-driven pulley rotates the rotor through the drive shaft. As the rotor rotates, the hydraulic pressure is applied to
the vane chamber of rhe rotor and the vanes will rotate while being pushed onto the inner circumference of the cam ring.
The inner circumference of the cam ring has an extended portion with respect to the center of the shaft, so the vanes
move downward in the axial direction as the rotor rotates. As a result of this roller movement. the internal volume of the
vane chamber will change, resulting in fluid intake and discharge
START OF FLUID INTAKE:FLUID INTAKE:FLUID MOVEMENT:FLUID DISCHARGE:
The vanes are pushed ontothe inner circumference ol the
cam ring,
lhe volume ofthe vane cham- The sucked-in fluid moves
ber increases so that fluid is toward the discharge port.
sucked in.
As the vanes return to the
their original Position on theinner side, the volume of the
vane chamber decreases so
the fluid is discharged from
the discharge port.
(cont'd)
a-t 4-I I- | t
FLOW CONTROL VALVE
J

Brake Booster InsPection
FunctionalTest
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress the pedal hard and hold it for 15 seconds lf
the pedal sinks' either the master cYlinder is
bypassing internally, or the brake system (master
cylinder. lines. modulator, proportioning control
valve, or caliPer) is ieaking.
2. Start the engine with the pedal depressed lf the
pedal sinks slightly, the vacuum booster is operating
normally. lf the pedal height does not vary, the
booster or check valve is faultY.
3. With the engine running. depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep. lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cvlinder is faulty. A slight change in
pedal height when the A'lC compressor cycles on
and off if normal. (The A/C compressor load
changes the vacuum available to the booster')
Leak Test
1. Depress the brake pedal with the engine running.
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises. the booster is
faulty.
2, With the engine stopped, depress the brake pedal
several times using normal pressure When the
Dedal is first depressed, it should be low On con-
secutive applications, the pedal height should grad-
uallv rise. lf the pedal position does not vary, checK
the booster check valve.
l./
19-23
Booster Check Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Stan the engine and let it idle. There should be vac-
uum. lf no vacuum is available, the check valve is
not working properly. Replace the brake booster
vacuum hose and check valve, and retest.
BRAKE BOOSTERVACUUM HOSE(Check valve
built-in)

-Starter Test
NOTE; The air temoerature must be between 59 and
100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described,
Alternate Procedurg:
. Use the following equipment:- Ammeter, 0 - 400 A
- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
- Tachometer, 0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NEGATIVETERMINAL
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section l1)
Check the Start€r Engagemont:
1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box,
2. Turn the ignition switch to START (llll with the shift
lever in E or E position (rVT) or with the clutch pedal
depressed {M/T). The starter should crank the engine.
. lf the starter does not crank the engine, go to
step 3.
. lf itcranksthe engineerraticallyortooslowly, go
to "Check for Wear and Damage" on the next
page.
Check the battery. battery positive cable, ground,
starter cut relay, and the wire connections for loose-
ness and corrosion, Test again.
lf the starter still does not crank the engine, go to
step 4,
Unplug the connector (BLK,/WHT wire and solenoid
terminal) from the starter,
Connect a jumper wire from the battery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem
. lf the startercranksthe engine, goto step 6.
Check the ignition switch (see page 23-891.
Check the starter cut relay and clutch interlock switch
(see page 23-86,87).
Check the A/f gear position switch (see page 23-154).
Check for an open in the wire between the ignition
switch and starter.
7.
(cont'd)
23-95
9.

l
Diagnostic Trouble Code (DTG) Chart -'96 - 97 Models
t
SRS indicator lightDTCPossible causeCorrectiv6 actionSae page
doesn't come on
none(doesn't
come on)
Faulty SRS indicator light circuitTroubleshooting24-26
comes on
none *4
(doesn't
go off)
Faulty SRS indicator light circuit, internal
failure of SRS unit, faulty SRS power supply.
Troubleshooting
24-29
1-1Open in the driver's airbag inflator24-42
lncreased resistance in the driver's aarbag
inflator24-42
l-3Short to another wire in the driver's airbag
inflator or decreased resistance
Short to Dower in the driver's airbag inflator
Short to ground in the driver's airbag inflator
24-44
1-424-46
1-524-48
2-1
With front passenger's airbag:
Open in the passenger's airbag inflator
Without front Passenger's airbag:
ODen in the dummy resistor
24-50
24-54
With front passenger's airbag:
Increased resistance in the passenger's airbag
inflator
Without front Passenger's airbag:
lncreased resistance in the dummy resistor
24,50
24-54
2-3
With front passenger's airbag:
Shon to another wire in the passenger's
airbag inflator or decreased resistance
Without tront passenger's airbag: Troubleshooting
Short to another wire in the dummy resistor
or decreased resistance
24-52
24-59
2-4
With front passenger's airbag:
Short to power in the passenger's airbag
inJlator
Without front Passenger's airbag:
Short to power in the dummy resistor
24-54
24-60
With front passenger's airbag:
Short to ground in the passenger's aarbag
inflator
without front passenger's airbag:
Short to ground in the dummy resistor
24-56
24-61
(cont'd)
24-17
a,

Troubleshooting
Diagnostic Trouble Code (DTCI Ghart -'96 - 97 Models (cont'd)
NOTE:* l: In case of an intermittent failure DTC g-1, it means there was an internal failure of the SRS unit or a faultv SRS indicator light circuit. Do the troubleshooting for intermittent failures (see page 24-15).*2: lt both DTC 9-2 and DTC 5-1 are indicated, do the troubleshooting for DTC g-2.*3: Apply to the '97 model coupe HX and DX.*4: DTC cannot be read with a Honda PGM Tester; check by jumping the SCS service connector.
24-18
.
Possiblg cause Cortestive action
5 3 I Internal failure of the SRS unitSRS unit
replacement
lnternal failure of the SRS unitSRS unit
replacement
Internal failure of the SRS unit
Internal failure of the SRS unitSRS unit
replacement
Internalfailure of the SRS unit ortwo failures at atime
8-6*3 Internalfailure ofthe SRS unit
Internal failure of the SRS unit
Faulty SRS power supply (VB line)
SRS unit replacement code (SRS unit must not
be used any longe.)
J

)Diagnostic Trouble Code (DTC) Chart -'98 - 00 Models
NEC SRS Unit
Ir
SRS indicator lightDTCPossible causeCorrestive actionSee page
doesn't come on
none
(doesn't
come on)
Faulty SRS indicator light circuitTroubleshooting24-26
comes on
none*3
(doesn't
go off)
Faulty SRS indicator light circuit, internal
fallure of SRS unit, faulty SRS power supply
(VB line)
Troubleshooting24-34
No DTC*3(lis ht
comes on
after self-
diagnosis)
Faulty SRS power supply (VA linelTroubleshooting24-39
l-1Open in the driver's airbag inflator
Troubleshooting
24 42
Increased resistance in the driver's airbag
inflator24-42
Short to another wire in the driver's airbag
inflator or decreased resistance24-44
't -4Short to power in the driver's airbag inflator24-46
t-5Short to ground in the driver's airbag inflator24-48
With front passenger's airbag:
Open in the passenger's airbag inflator
Without front passenger's airbag:
Open in the dummv resistor
24-50
24-54
With front passenger's airbag:
Increased resistance in the passenger's airbag
inflator
Without front passenger's airbag:
Increased resistance in the dummy resistor
24-50
24-58
with front passenger's airbag:
Short to another wire in the passenger's
airbag inflator or decreased resistance
Without front passenger's airbag:
Short to another wire in the dummy resistor
or decreased resistance
Troubleshooting
24-52
24,59
2-4
With front passenger's airbag:
Short to power in the passenger's airbag
inflator
Without front passenger's airbag:
Shon to power in the dummy resistor
24-54
24-60
With front passenger's airbag:
Short to ground in the passenger's airbag
inflator
Without front passenger's airbag:
Short to ground in the dummy resistor
24-56
24-61
(cont'd)
24-19
l,

Troubleshooting
Diagnostic Trouble Code (DTC) Chart -'98 - 00 Models {cont'dl
NOTE:* 1: In case of an intermittent failure DTC 9-1, it means there was an internal failure of the SRS unit or a faulty SRS indica-
tor light circuit. Do the troubleshooting for intermittent failures (page 24-'15).*2: In case of an intermittent failure DTC 9-2, it means there was an internal failure of the power supply {VB line). Do the
troubleshooting for intermiftent failures.*3: DTC cannot be read with a Honda PGM Tester; check by jumping the SCS service connector.
24-20
\
SRS indicator lightDTCPossible causeCorrectiYe actionSee page
comes on
5-1lnternal failure of the SRS unitSRS unit
replacemenl24-765-4
6-1
lnternal failure of the SRS unitSRS unit
replacement24-7 66-2
o-5
6-4
7-1
lnternal failure of the SRS unitSRS unit
replacement24-76
7-3
8-1lnternal failure of the SRS unitSRS unit
reptacement24-7 68-2
8-6Internal failure of the SRS unit or two failures
at a trmeTroubleshooting24-62
g_1*r *3lnternal failure of the SRS unitSRS unit
replacement24-7 6
9-2+2 *3lnternal failure of the SRS unit5l|5 Untr
replacement24-76
10-1SRS airbags deployed (SRS unit must be
reDlaced)
SRS unit
replacement24-76