262 HONDA CIVIC 1998 6.G Workshop Manual

Standards and Service Limits
Manual Transmission S40 - Section 13
MEASUREMENT
Capacity | (US qt, tmp qt)
End playDiameter of ball bearing contact area A(Transmission housing side)Diameter of 4th, 5th gear contact area BDiameter of 3rd gear contact area CDiameter of ball bearing contact area D(Clutch housing side)Bunout
STANDARD INEW}'1.9 (2.0, 1.7)for overhaul1.8 (1.9, 1.6) for oitchange
0.11 0.18 (0.004 _ 0.007)21.987 - 22.000 (0.8656 0.8661)
26.980 26.993 (1.0622 _ 1.0627)33.984 34.000 (1.3380 1.3386)25.917 - 25.99011.0227 1.0232)
0.02 (0.001) max.
SEBVICE LIMIT
ro
MainshaftAdjust21.930 (0.8634)
26.930 ('1.0602i33.930 (1.3358)
25.92011.0205)
0.05 (0.002)
39.07 ('r.538)
0.33 {0.013)0.31 (0.012)
30.15 (1.187)
30.05 (1.183)
37.07 {1.459)0.31 (0.0'12)
28.35 (1.116)
LrO
39.009 39.025 (1.5358 1.5364)0.06 0.21 (0.002 0.008)0.06 0.19 (0.002 0.007)30.22 30.21 (1.190 1.192)30.12 - 30.17 (1.186 1.188)
37.009 37.025 (1.4570 _ 1.4577)0.06 - 0.19 (0.002 - 0.007)28.42 - 2a.47 11.119,1.1211Countershaft Diameter of needle bearing contact area ADjameter of lst gear contact area gDiameter of ball bearing contact area CRunout
30.000- 30.015 {1.181 1 - 1.1817)35.984 - 36.000 (1.4167 1.4173)24.980 24.993 (0.9835 - 0.9840)0.02 (0.001)max.
29.950 (1.1791)3s.930 r.4146)24.930 (0.9815)0.0s (0.002)
End play (When tightened by the specified torque)Thickness
41.009 - 41.025 ('t.6145 1.6152)0.03 0.10 (0.001 _ 0.004)30.41 30.44 (1.197 - 1 198)
41 .01 11.617J0.22 (0.009)
30.36 (1.195)
gear End ptay (When tightened by the specified torque)44.009 - 44.025 (1.7326 1.7333)0.04 - 0.12 (0.002 - 0 005)31.91 31.96 (1.256 1.258)
44.01 11.t35)0.24 (0.009)
31.85 (1.2s4)
33.04 {1.301)38.93 (1.533)32.01 (1.260)
27.06 (1.065)
33.93 (1.336)
3r.93 {1.257)22.81 (0.898)
23.51 (0.926)
15.08 (0.594)
0.14 (0.006)
0.4 (0.016)
0.16 (0.006)
o.6210.0244112.78 (0.5031)
t.D.o. D.Length
33.000 - 33.010 (1.2992 1.2996)38.989 39.000 11.53s0_ 1.53s4)32.03 - 32.06 tl.261 - 1.2621Spacer collar(Mainshaft 4thand 5th gear)
Beverse rdler gear LD.Gear to reverse gear shaft cjearance
27.002 27.012 (1.0631 _ 1.0635)33.989 - 34.000 (1.3381 - 1.3386)3r.989 - 32.000 (1.2594 1.2598)22.83 - 22.86 (0.899 0.900)23.53 23.56 (0.926 - 0.928)
rs.016 15.043 (0.5912 _ 0.5922)0.032 0.077 (0.0013 _ 0.0030)Ring-to gear clearance {Ring pushed against gear)0.73 - 1.l8 (0 029 - 0.046)Fork finger thickness
Fork to-synchro sleeve clearance
lsv2nd/sth I 6.2 - 6.410.244 - O.ZS2)3rdl4th 7.4 i.6lO 2g1 O 2ggt0.35 - 0.65 (0.014 - 0.026)Beverse shitt fork Fork pawl groove widthFork to-reverse idler gear clearanceL groove widthFork'to-5th/reverse shift piece pin clearance
12.7 - 13.0 (0.50 _ 0.51)0.5 1. t (0.020 0.043)7 .05 - 7 .25 tO.21A - 0.28510.05 0.35 (0.002 0.014)Sh ift a rm A tnner diameter of sh ift arm C contact ffiShift arr14-go "L;L ".m C clearance13.05 13.13 (0.514 0.517)0.05 - 0.23 (0.002 _ 0.009)Inner diameter of shift arm B shaft contact pointShift arm 8-to shaft clearanceShift arm B to-shift piece clearanceDiameter of shift piece contact point
13.973 - 14.000 (0.5501 0.5512)0.013 0.070 (0.0005 _ 0.0028)0.2 - 0.5 {0.008 0.020)12.9 13.0 (0.508 - 0.512)MBS Shift prece Diameter of pin6.9 7 .1 \O.27 0 2A)
0.095 (0.004)
0.14 (0.006)
Adjust with shim
Differenlial carrier Pinion shaft bore diameterCarrier-to pinion shaft clearanceDriveshaft bore diameterCarrier to,driveshaft clearance
18.010 18.028 (0.7091 _ 0.7098)0.023 0.057 (0.0009 - 0.0022)26.025 26.04s {1.0246_ 1.0254)0.045 - 0.086 (0.0018 0.0034)BacklashPinion gear bore diameterPinion gear-to pinion shaft clearance
0.05 0.15 (0.002 0.006)18.042 - 18.066 (0.7103 _ 0.7113)0.055 - 0.095 {0.0021 _ o.oo37)
0 0.1 10 - 0.004)
3-8
LO

Standards and ServiceLimits
Section '14Automatic Transmission (cont'd)
UO
MEASUREMENTSTANDARD {NEW}
Wire Dia.o.D.Free LongthNo. ol CoilsHegulator valve spring ARegulato. valve spring BStator reaction springModulator valve springTorque convener check valve springCooler relief valve springRelief valve spring2nd oritice control valve spring1-2 shift valve spring2-3 sh ift valve spring3 4 shift valve spring'l st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd acc!mulator spring B2nd accumulator spring CLock up shift valve springLock up timing valve springLock-up control valve spring3 4 ofifice control valve springServo control valve springCPC valve springCPB valve spring4th exhaust valve spring
Springs1.8 {0.071)1.8 {0.071)4.5 \O.117)1.4 (0.055)
1.0 10.039)1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.035)
2.1 (0.083)
2.3 (0.091)
2.610.102)2.4 (0.094)
2.8 (0.'110)
1.6 (0.063)
2.2 (0.087)
2.2 t0.041)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.7 (0.028)
1.0 (0.039)
0.6 (0.024)
0.9 {0.035)0.9 (0.035)
14.7 (0.584)
9.6 (0.381)
3s.4 (1.407)
9.4 (0.374)8.4 (0.334)
8.4 (0.334)
8.6 {0.342)6.6 (0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)16.0 (0.636)10.2lo.402l17.0 {0.676)29.0 (1.152)
17.5 (0.6951
9.0 (0.358)
31.0 (1.220)
14.5 {0.576)7.6 (0.302)
8.1 (0.319)
6.610.262)6.6 (0.262)
8.1 (0.322)
5.6 (0.2231
8.1 10.322)6.1 10.242)
87.8 (3.457)
44.0 i.732l'30.3 (1.193)
35.0 {1.378)33.8 (1.331)
33.8 (1.331)
37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57.0 (2.2441
51 .0 \2.244189.1 {3.508)51.6 (2.031)
87.0 (3.425)
39.011.535)89.3 (3.516)
20.7 (0.815)
35.1 11.382)68.012.671173.7 12.902)80.7 (3.177)38.0 {1.496)37.5 fi.476)52.1 (2.051)
12.2 (0.480)
47.2 {1.858}36.4 {1.433)
16.511.01.910.94.24.213.422.016.326.826.a16.213.814.22.915.66.12.413.932.045.814.124.620.4
18.319.5
CVTSection 14
3-14
MEASUREMENTSTANDARD INEWISERVICE LIMITTransmissionfluidCapacity f {US qt, lmp. qt)6.4 {6.8, 5.6) for overhaul3.9 (4.1, 3.4) for fluid change
Hydraulicpressure
1kgflcm,, psi)
Forward clutch pressure at 1,500 rpm in E position1.4 - 1.15 114.3 - 11.A,203 - 2531Reverse brake pressure at 1,500 rpm in E position1.4 - 1.75 (14.3 11.8,203 2531Dr;ve pulley pressure at 1,500 rpm in E posrtrono.2 -0.7 12.0 -7.1,28- 1011Driven pulley pressure at 1,500 rpm in N positionr.5 - 2.3 115.3 - 23.5, 218 - 334)Lubrication pressure at 3,000 rpm in E posrtronAbove 0.212,30)Stall speed fpm (Check with vehicle on level ground)
E position
E, E, El positions2,5003,0002,350 - 2,6502,800 - 3, r00ClutchClutch initial clearance Forward clutchStart clutchReverse brakeClutch return spring free length Forward clutchStart clutchReverse brakeClutch disc thickness Forward clutchStart clutchReverse brakeClutch plate thickness Forward clutchSta rt clutchReverse brake
0.6 - 0.8 (0.024 - 0.031)0.5 - 0.7 (0.020 0.028)0.45 - 0.75 (0.018 - 0.030)30.5 {1.201)40.9 (1.610)
29.4 (1.157)
1.88 - 2.00 (0.074- 0.079)1.88 2.00 (0.074 - 0.079)1.94 - 2.06 (0.076 - 0.081)1.95 - 2.05 (0.077 -0.081)
2.25 2.35 (0.089 - 0.093)1.90 - 2.00 (0.075 0.079)
,*x.ar}38.9 (1.531)
27.411.019l'Until grooves worn out
Until grooves worn outDiscolorationDiscolorationDiscoloration
L.

\JExhaust Gas Recirculation System (D16Y5 engine with M/T)
M/T:
EGR VALVE 6P CONNECTOB (C14'rl
G10lIBLK}
1
a
PNK
IE.EGRI
Wi16 side of male terminals
I
sG2{GRN/BLK}
vcc2{YEL/BLU)
- Th6 MIL ha3 b€on reponed on.- DTC Pl,{tl is 3tored.
Prcblem verification:1. Do the ECM Reset Procedure.
2. Connect the SCS service con_nector.3. Start the engine. Hold the
engine at 3,000 rpm with no
load (transmission in neutral)
untilthe radiator fan comes on.
4. Drive the vehicle on the road
for approx. 10 minutes. Try to
keep the engine speed in the
1,700 - 2,500 rpm range.
lnlermittont tailure, svalem is OK
at thi3 tim6. Check foi Poor con'
nections or looso wiro3 at Cl/K
IEGR valvsl and ECM.
ls DTC P1491 indicated?
Check tor a malfunction in the
EGR valv6:1. Turn the ignition switch OFF.
2. Disconnect the EGR valve 6P
connector.3. Stanthe engine and let it idle
4. Measure voltage between the
EGR valve 6P connector termi'
nals No.4and No.6.
Check the EGR valve:1. Turn the ignition switch OFF2. Turn the ignition switch ON lll).3. Measure voltage between theEGR valve 6P connector termi
nals No.2 and No.3.
ls there battery voltage?
Substitute a known-good ECM
and recheck. It symptom/indica_tion goes away, replace th€ origi-
nal ECM.
ls there approx.5V?
(To page 11-262)

Emission Control System
(From page 11-261)
Check tor open in the wire (SG2
linel:Measure voltage between theECM connector terminals D10and D11.
Repsir open in lhe wire beiweenECM lOllland EGR valve.ls there approx. 5 V?
Check the EGR valve:1. Turn the ignition switch OFF.2, At the sensor side, measureresistance between the EGRvalve 6P connector terminalsNo. 1 and No. 2.
ls there continuity or resis-tance of 100 k0 or higher?
Check the EGR valve:Measure resistance between theEGR valve 6P connector terminals No. 1 and No.3.
ls there 100 k0 or higher?
Exhaust Gas Recirculation System (D16Y5 engine with M/T) (cont'dl
ECM CONNECTOR D {16P)
vcc2(YEL/BLU)
\v
sG2IGRN/BLK)
Wire side of female term;nals
EGR VALVE 6P CONNECTOR
EGR L(WHT/
BLK}
SG2 (GRN/BLK)
Termanal side of male terminals'l'
EGR L{WHT/BLK}
vcc2
{YEL/BLU}
(To pase 11 263)
1-262

T
t
lFrom page 11-262)
Chock for rn opon in the wire
{EGR L linel:1. Reconnect the EGR valve connector.2. Tu.n the ignition switch ON (ll).
3. Measure voltage betweon thePCM connector terminals Dgand Dl1.
Check tor th€ wirc (EGR L line):
Check for continuity betweenECM connector terminal Dg andbody ground.
ls there approx. 1.2 V?
Roprir op6n in the wirs botweanthe EGR valvo.nd th. ECM lD9).
Rooair ahort in tho wiro baftr,otn
tho EGR v.lv..nd the ECM lDgl.
Ch€ck the EGR valve:1. Turn the ignition switch OFF.2. Disconnect the EGR valve 6P
connector.3. Connect the battery positive
terminal to EGR valve 6P con-nectorterminal No. 6.4. Stan the engine and let it id'e,then connect the battery nega_
tive terminal to EGR valve 6Pcon nector term inal No, 4,
ECM CONNECTOR D I16P'
Wire side oI female terminals
EGR VALVE 6P CONNECTOR
wire sid6 of lemale te.minals
(cont'd)

I
ECM/PCM CONNECTOR A (32P)
2WBS(BLUIWiro side olIemaleterminalsJUMPER _
WIRE
EVAP BYPASS SOLENOIDVALVE 2P CONNECTOR {C793I
Wire side of
femal€terminals
\
ECM/P,CM CONNECTOR a l32Pl
Wir€ side of femaleterminals
(cont'dl
11-2A7
(From page 11-286)
Check the EVAP bypa3s 3olenoid
1. Turn the ignition switch OFF.
2. Connect ECM/PCM connectorterminal A28 and body ground
with a jumper wire.3. Turn the ignition switch ON (ll).ChGck tor an opon in lho wite(lGl lin6l:1. Turn the ignition switch OFF
2. Disconnect the 2P connectortrom the EVAP bypass sole-noid valve.3. Turn the ignition switch ON (ll).
4. Measure voltage between the
EVAP bypass solenoid valve
2P connector terminal No- 1
and body ground.
R.pair open in tha wil€ botwoonEVAP purg. cor|trol 3olenoid valve
.nd tho No. 15 ALTERNATOR SP
SENSOR 17.5 Al tu3e.
Check lor an open in the wire
{2WBS line):l. Turn the ignition switch OFF.
2. Reconnsct the 2P connectorto the EVAP bypass solenoid
3. Turn the ignition switch ON (ll)
4. Measure voltage between
ECM/rcM connector terminalsA28 and Al0.
Ch6ck the following P..ts for
l6akage to atmosPhere, and
roplir or rephco if neca3aary:' fuel fill c.D. tu6l t.nk. tuel vapor pipe. EVAP two way v3lvo. EVAP bypa3! solanoid vtlY., fuel tlnk pra63uro 3on3or. EVAP control canBte.. EVAP control crnistor vent
shut vtlvo. EVAP purgo control lolonoid
. vscuum hoseS and connoction3
Roprir opon in tho wiro betwoen
th. EVAP byp.$ 3ol6noid valve
rnd tho EcM/PcM lA28l.ls there battery voltage?
I2578t011'12tt15t6t8t9202321
2726293o
PGl (BLKI
I
II7l lslel ro lr' I't2r3,"l!j'"EBUP)._3)_!J
Ent ll4al*l 4 l,-'l
2WaS {BLUI
\

I)t
Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Measure the clearance between the countershaft
and lst gear.
Standard: 0.03 - 0.10 mm (0'(X)l - 0'qt4 in)
Sorvic. Limit: 0.22 mm (0.009 inl
2. lf the clearance is more than the service limit, mea-
sure the thickness of 1st gear.
Standard: 30./tl - 30.'l'l mm
11.197 - 1.198 in)
Servics Limit 30.36 mm (1.195 in)
lf the thickness of 1st gear is less than the service
limit, replace lst gear with a new one.
lf the thickness of 1st gear is within the service
limit, replace the lsv2nd synchro hub with a new
one.
GAUGE
1ST GEAB
3. Measure the clearance between 2nd and 3rd gears.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 in)
Servico Limit: 0.2,1 mm 10.009 in)
4. lf the clearance is more than the service limit, mea-
sure th€ thickness of the spacer collar'
stlndard: 32.G1 - 32'06 mm
{1.261 - 1.262 in}
S6rvica Limh: 32'01 mm (1'260 in)
SPACERCOLLAR
lf the thickness is less than lhe service limit, replace
the sDacer collar with a new one.
lf ths thickness is within the service limit, measure
the thickness of 2nd gear.
Standard: 31.91 - 31.96 mm
11.256 - 1.258 inl
Soryice Limit 31.85 mm (1.25,1inl
z4:_- 2I{D GEAF
/l\\/j'T - "b/
P-
1^'.-1r.--l--f
lf the thickness of 2nd gear is less than the ser-
vice limit, replace 2nd gear with a new one.
lf the thickness of 2nd gear is within the servace
limit, replace the lsv2nd synchro hub with a new
one,
13-21

CHECK BALL
w
MAIN VALVE BODY(Sectional viewl
SPRING SPECIFICATIONS
CHECK BALLS
CHECK BALLS
Unit: mm (in)
No.Springs
Standard (New)
Wire Dia.o.D.Free LengthNo. ot Coils
o
@
@
@
@
@
Relief valve spring
Modulator valve spring
CPB valve spring
1-2 shift valve spring
2nd orifice control valve spring
Servo control valve spring
1.1 (0.043)'1.4 (0.055)
0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
1.0 (0.039)
8.6 (0.342)
9.4 (0.374)
8.1 t0.3221
7.6 {0.302)
6.6 (0.262)
8.'t to.322l
37.1 (1.461)
35.0 (1.378)
47.2 (1.8s8)
41.3 (1.6261
34.8 (1.370)
52.1 t2.O51l
13.4
10.91C ?'15.3
22.0
20.8
1+143

Secondary Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanall parts thoroughly in solvent or carburetor cleaner. and drywith compressed air, Blowoutall passages.
. Replace the secondary valve body kit. P/N 27700 - P4R - 315 (The secondary valve body kit includes the linear solenoid
assembly) if any parts are worn or damaged.
. Checkall valves for free movement. lf anyfailto slide freely, seeValveBody Repairon page 14-139,
. Coat all parts with ATF during assembly.
. The CPC valve is installed in the secondary valve body, held in place by the lock bolt.
2.3 SHIFT VALVE
3.4 SHIFT VAL
.TH EXHAUST VALVE
LOCK BOLTCAUTION: Do not move.
SECONDARY VALVE BODYInspect for wear, scratches 6ndscoring.
3-'l ORIFICE CONTROL VAL
VALVE
SPRING SPECIFICATIONSUnit: mm (in)
No.SpringsStandard {New)
Wire Dia.o.D.Free LongthNo. of Coils
ora,.n
3-4 shift valve spring
2-3 sh ift valve spring
4th exhaust valve spring
3-4 orifice control valve spring
0.910.035)
0.9 {0.035)
0.9 {0.035)
0.7 {0.028)
7.6 (0.302)
7.6 (0.302)
6.1 10.2421
6.6 (0.262)
57 .O 12.2441
57 .O 12.2441
36.4 (1.433)
37.5 (1.476)
26.8
26.8
24.6
14-144

Regulator Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air. Blowoutall passages
. Replace the valve body as an assembly if any parts are worn or damaged.
. check allvalves for free movement. lf anyfail toslidetreely, see valve Body Repairon page 1+139.
1. Hold the regulator spring cap in place while removing the stop bolt. once the stop bolt is removed. release the spring
cap slowly.
CAUTION: The regulator 3pring cap can pop out when the stop boh is removod'
2. Reassembly is the reverse order ofths disassembly procedure.
NOTE:
o Coat all parts with ATF during assembly.
. Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve
body, and tighten the stop bolt.
STOP BOLT6x1.0mm12 N.m 11.28.7 tbf.lrl
^/^'ou*'oRsPRrNGcAP
*N@
REGULATOR VALVE
\=f -.-*
*fi /F { a-tLocK.uPcoNrRoLvALVE
cooLERRELlEFvALVr"r?
ry
roRouE coNvERrER cHEcKv ^LvE//
v ^r* "r**::f vi{LvE cAp
SPRING SPECIFICANONS
REGULATOR VALVE BODY
Inspect lor wear, scratches
and scorlng.
Unit: mm (in)
No,Springe
Standard (Now)
Wire Dia.o.D.Free LengrthNo. of Coils
o
o
@
@
@
Regulator valve sPring A
Regulator valve spring B
Stator reaction spring
Cooler relief valve spring
Torque converter check valve spring
Lock-up control valve sPring
1.8 {0.07'r)
1.8 (0.071)
4.5 (0.177)
1.0 (0.039)
1.0 (0.039)
0.7 (0.028)
'r4.7 (0.584)
9.6 (0.381)
35.4 (1.407)
8.4 {0.334)
8.4 {0.334}
6.6 {0.262}
87.8 (3.457)
44.0 (1.732)
30.3 (1.193)
33.8 (1.331)
33.811.3311
38.0 {1.4961
11.0
1.9
8.2
a.2't 4.1
14-145