500 HONDA CIVIC 1998 6.G Service Manual

Troubleshooting Flowchart - Shift Control System
NOTE: Record all freeze data before you troubleshoot.
Po$ible Cause
Faulty 3hift control systemOgD ll Scan Tool indicates Code
P'1890.Self-diagnosi3 E indicator light
indicates Code 42.
Check for Anolhet Code:
Check whether the E indicator
light indicates another code.
Pertorm the TroubleshoolingFlowchrrt to. th€ indicet.d
Codelsl.
ls the E indicator light indi
cate another code?
Check Stall Speed RPM:Measure the stall speed RPM(see page 14-298).
ls the stall speed over 3,500 rpm?
ls the slall speed below 2.0o0 rpm)
Test-drive and Check E ngine
Speed:1. Drive the vehicle at 30 mPh(50 km/h) constantlY for sev_
eral manutes.2. Check the engine speed
ls the engine speed within the
specification (see page 14 296
and 14 297\?
14-259

From page 14 260
Check Stall Speed RPM:
Measure the stall speed RPM (see
page 14'298).
ls the stall speed over 3,500 rpm?
Warm Up Engine and Recheck
Failure:1. Warm uP the engine to nor'
mal operating temPerature(the radiator fan comes on)
2. Check whether the start clutchproblem appears again.
Does the problem appear?
The svstem is OK at this time.
rl,
J
14-261

Troubleshooting Flowchart - Shift Control System
NOTE: Record allfreeze data before you troubleshoot
Possible cause
Faultv shift control svstem' OBD ll Scan Tool indicates Codo
P1Ato.. Self-diagnosis E indicator light
indicatos Code 42.
Check for Anoth€r Code:Check whether the E indicator
light indicates another code.
P€rform the Tloubleshooting
Flowchart for the indicated
Code(sl.
ls the E indicator light indi
cate another code?
Check Stall Speed RPM:
Measure the stall sPeed RPM(see page 14-298).
ls the stall speed over 3,500 rpm?
ls the stall speed below 2,000 rpm?
Test-drive and Check Engine
Speed:L Drive the vehicle at 30 mph
150 km/h) constantly for sev-
eral mlnutes.2. Check the engine speed
ls the engine speed within the
specification (see Page 14'296
and 14'297)?
14-245

at
aI
From page 14'286
Check Srall Speed RPM:Measure the stall speed RPM (see
page 14-298).
ls the stall speed over 3,500 rPm?
Warm Up Engine and Becheck
F ilure:1. Warm up the engine to nor
mal operatang temPerature(the radiator fan comes on).
2. Check whether the stan clutchproblem appears again.
Does the problem appear?
The 3v3tem ia OK at thi! iime.
14-2a7

o @ position: Engino Speed rPm
Throttle Opening
Vehiclo Speed
-25 mph l/() km/h) | 37 mph {60 km/h) | 62 mph {100 km/h}
Throttle position sensor voltage: 0.75 V1,250 - 1,650
Throttle position sensor voltage: 2'25 V2,500 - 3,1002,650 - 3,2502,700 - 3,300
Throttle position sensor voltage; 4 5 V
Full throttle position3,950 - 4,5504,650 - 5,2505,200 - 5,800
o $l position: Engine Speed rPm
Throttle Oponing
Vehicle Spoed
2s mph (40 km/hl | 37 mph (60 km/hl | 62 mph {r00 km/h}
Throttle position sensor voltage: 0.75 V1,800 - 2,2002,200 - 2,8003,550 - 4,150
Throttle Dosition sensor voltage: 2.25 V2,950 - 3.5503,250 - 3,8504,050 - 4,650
Throftle position sensor voltage: 4.5 v
Full throftle position4,100 - 4,7005,100 - 5,7005,900 - 6,500
o E position: Engin€ Sp6ed rPm
Throttle Oponing
Vehiclo Spoed
25 mph (40 km/hl | 37mPh{60km/h) J 62 mph 1100 km/h}
Throttle Dosition sensor voltage: 0.75 V3,100 - 3,7003,650 - 4,2504,450 - 5,050
Throttle position sensor voltage; 2.25 V3,500 - 4,1004,050 - 4,6504,800 - 5,400
Throttle position sensor voltage: 4.5 V
Fullthrottle position4,100 - 4,7005,100 - 5.7005,900 - 6,500
14-297

Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not test stall sp€€d for mole than 10 seconds at a time.
. Do not shift the lsver whils raising the engine speod.
. Be sure lo remove the pressure gauge before tosting stall speed.
. Stall speed tssts should be used tor diagnostic purposes only,
1. Engage the parking brake, and block the tront wheels.
2. Connect a tachometer to the engine, and stan the engine.
3. Make sure the A/C switch is OFF.
4. After the engine has warmed up to normal operating temperature (the radiator fan comes on), shift into E position.
5. Fully depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed,
6. Allow two minutes for cooling, then repeat the test in E, E, and E positions.
Stall Speed BPM in E poshion:
Specification: 2,500 rpm
Servic€ Limit: 2,350 - 2.650 rpm
Stall Speed RPM in E, E and E positions:
Specitication: 3,000 rpm
Service Limit: 2,800 - 3,100 rpm
TROUBLEPROBABLE CAUSE
Stall rpm high in @. p. [, and @ positionsLow fluid level or ATF pump output
Clogged ATF strain€r
PH regulator valve stuck closed
Slippage of forward clutch
Faulty start clutch
Stall rpm high in E position. Slippage of reverse brake. Faulty start clutch
Stall rpm low in E, P, [, and @ positionsEngine output low
Faulty stan clutch
Stuck shift valve
14-294

1.
Start the engine.
Shift to the respective shift lever positions in the table, and measure the following pressures at 1'500 rpm'
. Forward Clutch Pressure
. Reverse Brake Pressure
. Drive Pulley Pressure
. Driven Pulley Pressure
8. Shift to E posltion, and measure the lubrication pressure at 3,000 rpm'
Disconnect the special tool after pressure testlng
Install the sealing boits in the jnspection holes with new sealing washers, and tighten the bolts to the specified
toroue.
TOROUE: 18 N.m {1.8 kgf'm, 13 lbf'ft}
CAUTION: Keep all foreign particles out of the transmission'
9.
10.
PBESSURESHIFT LEVER
POSmONSYMP{OMPROBABLE CAUSE
FLUID PRESSURE
Standard/Ssrvice Limit
Forwa rd
Clutch
ENo or low for-
ward clutch
pressure
Forward Clutch1.4 - 1.75 MPa
(14.3 - 17.8 kgtcm', 203 - 253 Psi)
Reverse
Brake
tsNo or low
reverse brake
pressure
Reverse Brake1.4 - 1.75 MPa
(14.3 - '17.8 kg7cm', 203 - 253 Psi)
Drive
Pulley
NNo or low
drive pulley
pressure
ATF pump, PH reg-
ulator valve, PL
regulator valve,
Shift valve
0.2 - 0.7 MPa
(2 - 7.1 kgflcm', 28 - 101 Psi)
Drive pulley
pressure roo
high
PH regulator valve,
PL regulator valve,
Shift valve. Shift
control linear
solenoid
Driven
Pulley
No or low
driven pulley
pressure
ATF pump, PH reg-
ulator valve, Shift
valve, Shift control
linear solenoid
1.5 - 2.3 MPa
(15.3 - 23.5 kg?cm', 218 - 334 Psi)
Driven pulley
pressure too
h igh
PH regulator valve
LubricationNo or low
lubrication
pressure
ATF pump,
Lubrication valve
Above 0.2 MPa
(Above 2 kgf/cm'. 30 Psi)
14-301

Flywheel Housing
Bearing
Secondary Gear Shaft Bearing
Replacement
1. Remove the secondary gear shaft bearing using the
special tools as shown.
3/8" - 16 SLIDE HAMMER
{Comm6rciallY availablel
SECONDARY GEAR
ADJUSTABI.T BEARING SHAFT BEARINGPULLER.25 - 40 mm07736 - A01000A
Install the new secondary gear shaft bearing until it
bottoms in the transmission housing. using the spe-
cial tools as shown.
Secondary Gear Shaft Bearing
Replacement
1. Remove the secondary gear shaft bearing using the
soecial tool as shown.
3/8" - 16 SLIDE HAMMER
lCommorcially aY.ilabl6l
2. lnstall the new secondary gear shaft bearing until it
bottoms in the flywheel housing, using the special
tools as shown.
DRIVER07749 - (x)10000
ATTACHMENT.62xGgmm07745 - 0010500
14-335

Ref. No I Tool NumberDescriptionOty I Pag€ Reterence
o
@
@
@
@
fof
@
@
@
@
@
@
@
@
@
@
@
@
@
07GAF - PH70100
07GAG - SD4010A or
07GAG - SD40100
07GAG - SD4020A or
07GAG - S040200*07JGG - 00r 010A
07MAC - 5100200
OTNAD - SR3O2OA
07NAG - SR3090A or
07NAG - SR30900
07RAK - 5040110
07RAK - 5040121 or
07RAK - 5040t20
07406 - 0010004 or
07406 - 001000r
07725 - 0030000
07746 - 0010100
07746 - 0020100
07746 - 0030300
07749 - 0010000
07916 - SA50001
07965 - SA50500
07974 - SA5020A or
07974 - SA50200
07974 - SA50800
Pilot Collar
Piston Seal Ring Guide
Piston Seal Ring Sizing Tool
Belt Tension Gauge
Ball Joint Remover, 28 mm
Cylinder End Seal Bemover Attachment
Piston Seal Ring Sizing Tool
P/S Joint Adaptor (Pump)
P/S Joint Adaptor (Hose)
P/S Pressure Gauge
Universal Holder
Attachment,32 x 35 mm
Driver, 22 mm l.D.
Attachment, 30 mm l.D.
Driver
Locknut Wrench, 40 mm
Front Hub DiVAssembly Tool
Sleeve Seal Ring Sizing Tool
Bsll Joint Boot Clip Guide
1
1
'I
1'I
1
I
1
1
I
1
1
I
1
1
I
1
I
11-54
17-59
'17-59
17 -32
17 -6, 47
17-51
| /-ao
17 -34
17 -31
't7 -34
't7-42, 16
17-57,58
17-10
17-44't7 -57
17-5,33
17-68
17 -57
17-57, 6A* lncluded in the Belt Tension cauge Set, 07TGG - OO10OOA.
o
p
v
@o
€_
ts7-dysB
aal
@@
(o)
F=1
@@@
@@@
17-2

Steering Gearbox
l.r
Rack Guide Adjustment
NOTE: Perform the rack guide adjustment with the
wheels in the straight ahead position.
1. Loosen the rack guide screw locknut with the spe-
cial tool, then loosen the rack guide screw.
LOCKNUT WRENCH, 40 mm07916 - SA5000r
Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loosen
rt.
Retighten the rack guide screw to 4 N'm (0.4 kgf m,
2.9 lbf.ft), then back it off to specified angle.
Specilied Return Angle: 30' max.
Tighten the locknut while holding the rack guide
Check for tight or loose steering through the com-
plete turning travel.
Recheck steering effort (see page 17-4).
4.
RACK GUIDE SCREW
l,z
Removal
NOTE: Using solvent and a brush, to wash any oil and
dirt off the gearbox. Blow dry with compressed air.
1. Raise the front of vehicle, and support it on satety
stands in the proper locations (see section I ).
2. Remove the front wheels.
3. Remove the steering wheel (see page 17-35).
4. Remove the steering loint cover
Remove the steering joint lower bolt, and discon-
nect the steering joint by moving the joint toward
the column.
(cont'd)
17-5
STEERING JOINT COVER
LOWER BOLT
STEERING JOINT