HONDA CIVIC 1999 6.G Workshop Manual

l.
60. Install the ditferential assembly
61. Installthe ATF passage line assembly with new O-rings (one boltl'
62. Install thethreedowel pinsand new flywheel housing gasket on the transmission housing'
63. Install the flywheel housing and connector bracket (twenty bolts)'
64. Installthe ATF passage line holder assembly (two bolts)'
8 x 1.25 mm29 N.m t3.o kg['m, 22 lbf'ttl
IATF PASSAGE L|NE I"o.o.'o{
d

rm
\A
o-nrnc--.-..ff
FLYWHEEL HOUSINGGASKET
6x1.0mm12 N.m {1.2 ksf'm,
8.7 tbf.ftl/g
ugs llFLYWHEEL HOUSING
CONNECTOR BRACKET
DOWEL PIN
DIFFERENNAL ASSEMBLY
DOWEL PIN
ATF PASSAGE LINE
ASSEMALY
6x1.0mm12 N.m 11.2 kgd'm,
8.7 tbr.tr)
O.RING
DOWEL PIN
TRANSMISSIONItousrNG
ATF PASSAGELINE ASSEMBLY
PASSAGE LINEGUIOE
(cont'd)
TRANSMISSION HOUSING
14-345

Transmission
Reassembly (cont'dl
65 lnstall the solenoid harness connector with a new O-ring (one bolt), then install the lower valve body assembly withthree dowel pins (eight bolts).
66. Install the ATF strainer with a new O-ring (two bolts).
67. lf necessary, assemble the ATF pan, ATF filter, and the ATF cooler inlet line (see page 14_303).
68. Install the ATF pan with the two dowel pinsand a new ATF pan gasket (fourteen bolts).
69. Install the ATF cooler inlet line bracket bolt.
70. Installthe ATF cooler outlet line with the line bolt and new sealing washers.
6x1.0mm12 N.m 11.2 kgf.m,8.7 rbtft)DOWEL PINS
ATF STRAINER
DOWEL PINS
ATF PAN,/ATF FILTER/ATF COOLER INLETLINE ASSEMELY
@
@
C4
CONNECTOE
6x1.0mm12 N.m {1.2 kgf.m,8.7 tbtftl6x1.0mm12Nm11.2kgl.m,8.? tbf.ft)
LOWER VALVE BODYASSEMBLY
6x1.0mm12 N.m 11.2 kgf.m,8.7 tbt.ft)
ATF COOI.ER INI.ITLINE BRACKET BOLTI x 1.25 mm26 N.m (2.7 kgt.m, 20 lbf.ft)
ATF COOLER OUTI.IT LINE
14-346

Flywheel/Drive Plate
DRIVE PLATE
/,1vl
a
o0
a9
WASHERInstall in this direction.
FLYWHEELlnspect the teeth of the ring gear for excessive wear'
../
.t
12 x 1.0 mm74 N.m (7.5 kgf.m, 54lbfft)
Torque in a crisscross Pattern

Transmission
Installation
Flush the ATF cooler as described on pages 14-352and 14-353.
Remove the used grease in the flywheel hub caDand flywheel splines.
Fill the inside of the flywheel hub cap, and coat the fly-wheel hub splines with Super High Temp Urea Grease(P/N 08798 - 9002) as shown.
L
SEALING RING{RUEBER)
SPLINESApply SUPEB HlcH TEMPUREA GREASElPlN 08798 - 90O2t
SUPER HIGH TEMPUREA GREASE(P/N 08798 - !)00211.5-2.5 g 10.05-0.t9 oz)
Install a new sealing ring (rubber) on the inoutshaft, and install two '14 x 20 mm dowel Dins in theflywheel housing.
Install the flywheel securely on the input shaft, theninstallthe starter motor on the flywheel housing.
4,1Nmla.5 kgt.m, 33 tbt.ft)
INPUT SHAFT
STARTER
l4 x 20 mm DOWEL ptN
.4;i "lrj
,i rr,"r., ., a
14-348
FLYWHEEL
MOUI{T74 N.m (7.5 tstm,5a tbtftt
6. Place the transmission on s jack, and raise it to theengine assembly level.
7. Anach the transmission on the engine, then installthe transmission housing mounting bolt and rearengine mounting bolts.
TRANSMISSION HOUSINGMOUNTING BOIT6,1 N.m 16.5 kgl.m,47 tbtttl59 Nrn {6.0 kgl.m. ,€ lbt ftl
WASHER
lnstall the transmission mount bracket. Tighten thelong bolt loosely, and tighten the nuts and bott onthe mount bracket to the specified torque. Thentighten the long bolt to the specified torque.
REAR ENGINE MOUNTINGBOLTReplace.12 x 1.25 mm
12x 1.25 mn6,r N'm 16.5 kgtm,47 tbtftl
l-".--..-,^
G\V
TRANSMISSONMOUNT BRACKET
12 x 1.25 mn

l.
9. Install the remaining transmission housing mount-
ing bolts.
PRIMARY OXYGEN SENSOR
Remove the transmission jack and the hoist. then
remove the hoist bracket from the engine'
Attach the flvwheel to the drive plate with eight
bolts and torque as follows:
Rotate the crankshaft pulley as necessary to tighten
rhe bolts to half of the specified torque, then to the
final torque, in a crisscross pattern.
After tightening the last bolt. check that the
crankshaft rotates freelY.
10.
11.
12. Install the flywheel cover and the engine stiffeners
DRIVE
6xl.0mm12 N.m
- l12 kgf'm'rE 8.7 tbf.ftl
ENGINESTIFfENEB10 x 1.25 mmart N.m la.s kgt.m,33 tbtftt
8 x 1.25 mm24 N.m(2.1 kgf'm,17 tbt.ftt
DRIVE PI.ATE BOLT
6x1.0x14mm12 N.m {1.2 kgt m.
8.7 lbf,ftl8 x 1.25 mm26 N.m
12.7 kqfin,20 rbt'ftlFLYUTHEEL
ENGINE STIFFENER
8 x 1.25 mm10 x 1.25 mmr,a N.m {4,5 kgf m,
33 tbf.ftl
TRANSMISSION HOUSING
MOUNNNG BOLT
6il N.m {6.5 kgf.m, 47 lbf'ftl
24 N.m (2.4 kgt'm, '17 lbf'ftl
22 N.m t2.2 kgl m, 16lbf'ftl
14-349
13.
14.
Tighten the crankshaft pulley bolt, if necessary (see
section 6).
Connect the ATF cooler hoses to the ATF cooler lines
(see page 14-357).
CAUTION: Whilo connecting the ATF cooltr hGes,
b€ sure not lo allow dust and other loreign parti-
cles to entg. into the transmission.
15. Installthe right front mounvbracket'
10 x 1.25 mm
a,r N.m {4.5 kgf'm,33 lbt ftl
RIGHT FRONTMOUNT/BRACKET
ATF COOLER LINE
10 x 1 .25 mm54 N.m {5.5 kgt'm,
4{) tbl.ftt
ATF COOI,TR HOSE
16. Installthe exhaust PiPe A.
EXHAUST PIPE A
GASKETReplace.
@
\SELF.LOCKING NUTReplace.10 x 1.25 mm5/a N.m {5.5 kgt m,irc lbf.ft)
(cont'dl
*s$o
oor*rr-@Replace.
SELF.LOCKINGReplace.8 x 1.25 mmSELF.LOCKING NUT
Replace.8 x 1.25 mm16 N.m {1.6 kgl'm,12 tbl.ftt

Transmission
17.
Installation (cont'd)
Install I new set ring on the end of each driveshaft.
Install the right and left driveshafts (see section 16).
CAUTION: While instatling the drive3hafts in thedifferential, be sure not to allow dust and olher for-aign particles to enter into tho transmission.
NOTE:
. Clean the areas where the driveshafts contact thetransmission {differential} thoroughly with sol-vent or carburetor cleaner, and drv with com-
Dressed air.
. Turn the right and left steering knuckle fully out-wa.d, and slide each driveshaft into the differen-tial until you feel its set ring clip engage the sidegear.
Install the damper fork, then install the right and leftball joints to each lower arm with the castle outsand new cotter pins.
19.
10 x 1.25 mm43 N.m{4.4 kgf.m, 32 lbf.ftl
SELF-LOCKING NUTReplace.12 x 1.25 mm6l N.m
CASTI.I'12 x 1.25 mm
{6.s ksr.m. 47 tbr.ftr l! _ ll ffiteo
- s.o tet'.,
14-350
20. Install the splash shietd.
aa
I6I6*
"a,a s
21.
SECONOARY GEARSHAFT SPEEDSENSOB CONNECTOR
6 x 1.0 mm9.8 t{.m 11.0 kgt.m,7.2 tbf.trl
Connect the vehicle speed senso. connector. thedriven pulley speed sensor connector and the sec-ondary gear shaft speed sensor connector,
6x1,0mm12 N.m {1.2 kg{.m, 8.7 tbf,ft)
DRIVEN PULLEYSPEED SENSORCONNECTOR
E.
6 x 1.0 m.rl'12 N.m {1.2 kg{.m,8.7 tbf.fo

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

Transmission
Gooler Flushing
@ To prevent iniury to face and eyes, alwayswear safety glasses or a tace shield when using thetransmission flusher.
NOTE: This procedure should be performed before rein-stalling the transmission.
'1. Check the tools and hoses for wear and cracks before
using. lf wear or cracks are found, reDlace the hoses
before using.
4.
Using the measuring cup. fill the tank with 2,1 ounces(approximately 2/3 full) of biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontatner.
Secure the flusher filler cap, and pressurize the tankwith compressed air to between 5S0 - 829 kpa (5.6 -
8.45 kgf/cm', 80 - 120 psi).
NOTE: The air line should be equipped with a watertrap to ensure a dry air system,
Hang the tool under the vehicle.
Attach the tank's discharge hose to the return lineoi 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 ofthe drain hose to abucket or floor drain,
t
TRANSMISSION COOLERFLUSHER{Commercially available)Kent-Moore J384O5-Aor oouivalent
TRANSMISSION
14-352
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
8. Turn on the flusher water valve so water will flowthrough the cooler for 10 seconds.
NOTE: lf water does not flow through the cooler, itis completely plugged, cannot be flushed, and mustbe replsced.
9. Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
'10. While flushing with the water and flushing fluid fortwo minutes. turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgflcmr, 120 psi)
11. Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
12. Release the trigger. and rinse the cooler with wateronly 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 airfor two full minutes or until no moisture is visibleleaving the drain hose.
CAUTION: Rosidual mobturo in the qooler or linescln damage the transmission,
15. Remove the flusher from the cooler line. Attach thedrain hose to a container.
16. Install the transmission. and leave the drain hoseattached to the cooler line.

l.
17.Make sure the transmission is in the E] position.
Fill the transmission with cvT Fluid, and run the
engine for 30 seconds or until approximately 0 95 {
(1.0 US qt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the cooler
return hose to the transmission (see page 14-355)
Refill the transmission with CVT Fluid to the proper
level (see page 14-299).
18.
'19.
.l ,
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with water
and pressurize the can. Flush the discharge line to
ensure that the unit is clean.
2, lf discharge liquid does not foam, the orifice may be
blocked.
3. To clean, disconnect the plumbing from the tank at
the large couPling nut.
FILTER
\
\- 0--D
i
I
O.RING
Remove the in-line tilter from the discharge side and
clean if necessary'
The fluid orifice is located behind the filter. Clean it
with the pick stored in the bottom of the tank han-
dle. or blow it clean with air. Securely reassemble
all parts.
COUPLINGNUT
II
-@q
\ORIFICE
FILLER CAP
14-353

Shift Cable
RemovaUlnstallation
@ Make sure lifts, iacks and safety stands are
placed properly (see seqtion 11,
1. Remove the front console (see section 20).
2. Shift to E position, then remove the lock pin from
the adiuster.
ADJUSTER
14-354
Remove the air cleaner housing assembly.
Remove the clip from the control lever, and loosen
the locknut.
CLIP SHTFT CABLE LOCKNUT29 N.m 13.0 kgf m,22 lbf.ft)
SHIFT CABI-EBRACKET
7.
8.
CONTROL LEVER
Remove the shift cable from the control lever, the
shift cable bracket, and the clamp.
Remove the shift cable bracket bolts and nuts, then
remove the shift cable. Take care not to bend the
shift cable when removing/installing it.
SHIFT CABLE BRACKET
lnstall the shift cable in the reverse order of removal.
Check the cable adjustment (see page 14-355).
\.
*o"ra" \
{1.2 kgI m, 8.7 lblft)