Iat HONDA CIVIC 1999 6.G Workshop Manual

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

Shift Valve BodY
The shift valve body contains the shift valve and the shift control valve. Both are ioined to the shift control linear solenoro.
r tl'ft1il1rf"","" is controred by shift varve pressure (sV) from the shift contror varve. The shift varve distributes pH
pi""aur" "nO PL pressure to drive pulley and the driven pulley' to shift the transmission'
t t*"rilf:::lr';ivarve contrors the shift varve in accordance with the throttre opening and vehicle speed rhe shift
control valve is convorr"o uv ti" "iirt "ontrol linear solenoid, which is controlled by the TcM or PcM When the elec-
tronic control system is faulty, t;; snift controt uutue "witches the shift inhibitor valve to uncover the port leading the
pitot regulator pressure to the start clutch
CONTROL VALVE
VALVE BODY
T;J:"i"""1ff"t""ilody contains the manuar varve and the reverse inhibitor varve. The manuat varve bodv is borted to the
intermediate houslng
. ManualValve
The manual valve mechanicallY uncovers/covers the fluid passage according to the shift lever position'
'
ff:e;;;.'::'?Xftl::T",* is contro ed by the reverse inhibitor pressure (Rl). lt intercepts the hvdraulic circuit to the
reverse brake while the vehicle is moving forward at speeds over approximatelv 6 mph (10 km/h)'
REV€RSE INHIBITORVALVE
MANUAL VALVEBODY
SHIFT CONTROL
MANUAL VALVE
14-211

E Position
Astheengineturns.theATFpumpa|sostartstooperate.F|uidfromtheATFpumpf|owstothePHregu|atorva|veandthe
c|Utchreducingva|ve.ThePHregu|atorva|veregu|ateshighpressure(PH).andsendittotheshiftVa|veandthePLregU'
latorvalve.Thehighpressure(PH)flowstothemovablefaceofthedrivenpulleyviatheshiftvalve'andturnsintolow
pressure(PL)atthePLregu|atorva|ve.Thelowpressure(PL}f|owstothemovab|e'aceofthedrivepu||eYviatheshift
valve. At this time, the pulley ratio remarns low'
Thehighpressure(px)uecomesttrectutchreducingpressure(CR)atthec|utchreducingva|Ve.Thec|utchreducingpres.
sure (CR) flows to the start clutch cont'oi uatt". tn"lt"n'al valve' the PH-PL control valve' and the shift control valve' and
is intercepted bY those valves
Under this condition, hydraulac pressure is not applied to the clutches and reverse brake'
(cont'd)
14-213

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

Troubleshooting Procedures
(cont'd)
C. lf the inspection for a particular code requires voltage or resistance checks at the TCM or PCM connectors, removethe driver's side kick panel, and unbolt the TCM, and at the PCM connectors, remove the passenger's side kickpanel, and unbolt the PCM. Turn the ignition switch OFF, and connect the backprobe sets and a digital multimeteras described below. Check the system according to the procedure described for the appropriate code(s) listed onthe following pages.
6x1.0mm9.9 N.m {1.0 kgt m,
How to use lhe Backprob€ SE{
Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter, Using the wireinsulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from thewire side until comes in contact with the terminal end of the wire.
BACI(PROBE SET07saz - 001 txtoaItwo requirodlDIGITAL MULTIMETER(Commarcially avsibblelKS-AHM-32-(x)3,or oquivalent
6 x 'l,0 mm9.E N.m (1.0 kgf.m,7.2 rbtftt
coRo
14-236
ADAPTER

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

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

Start Clutch Control@
T
Start Clutch Calibration Procedure
NOTE: When the following parts are replaced, the TCM
must memorize the feedback signal for the start clutch
control.
. TCM
. Transmissionassembly
. Stan clutch assembly
. Lower valve bodv assembly
. Engine assembly or overhaul
'96 Model Only
CAUTION: Do not uso this procsdure on'97 - (X) mod-
els or you will damage the transmission. On '97 - 00
models, the TCM or PCM memorizes ths loodback sig'
nals when you drive the vehicle.
1. Engage the parking brake, and block the front
wheels securely.
2. Connect the SCS service connector to the Service
Check Connector as shown. (The Service Check
connector (2P) is located under the dash on the
passenger's side of the vehicle.)
CONNECTOR07PAZ - lDl01(xt
Start the engine, and warm it up to normal operat-
ing temperature (the radiator fan comes on twice).
Fully depress the brake pedal and accelerator for 20
seconds in the E] position.
rl ,
CONNECTOR I2PI
14-293
7.
Shift into E o|. E position. To store the engine
negative pressure in memory. Iet the engine idle in
E or E position for one minute under the follow-
ing conditions:
. With the brake pedal depressed,
. with the y'\/c switch oFF.
. With the combination light switch OFF.
. With the heater fan switch OFF.
. Turn OFF all other electrical systems
NOTE: Start step 5 within 60 seconds after the radi-
ator fan goes off.
Shift into E position, and let the engine idle for two
minutes to store the feedback signal in memory
under the same conditions as in step 5.
Connect the Honda PGM Tester. Check that the TCM
has completed the start clutch calibration.
NOTE:
. The TCM will not store the feedback signal when
the CVT fluid temperature is below 40"C (104'F)
even if the engine coolant temperature reaches
the normal operating temperature.
. Repeat these procedures until the start clutch
calibration is completed-
Disconnect the SCS service connector from the
Service Check Connector.
'97 - 00 Models
The TCM ('97 - 98 models) and PCM ('99 - 00 models)
memorize the feedback signal when you drive the
vehicle as follows:
. After warming up the engine (the radiator fan
comes onl.
. Shift into E position.
. Turn OFF all electrical systems,
. Drive the vehicle up to the speed 37 mph (60
km/h).
. After the speed reaches 37 mph (60 km/h),
release the accelerator for 5 seconds.

t.
rl,
fl,
PROBABLE CAUSE LIST
Low CVT fluid level
ATF pump worn. AT gears worn or damaged. Foreign material in ATF pump.
ATF pump chain/ATF pump sprocket worn or damaged.
Input shaft worn or damaged.
Sun gear worn or damaged.
Final driven oear worn or damaqed,
Secondary drive gear/secondary driven gear worn or damaged-
5
6
1
8Flywheel/drive plate worn or damaged.
Intermediate housing assembly worn or damaged.9
'10Forward clutch defective.
Shift cable broken/out of adiustment.
M"nu"t t"uffi
ATF feed pipe (pulley pressure) worn or damaged.
Vchiclc speed sensor defective.
TCM or PCM defective.
Reverse brake detective.
1'r
't2
13
14
16
'11
'18
1qPlanetary gear worn or damaged.
Sta rt clutch defective.
ATF feed pipe (start clutch pressure) worn or damaged
20
t't
Clutch clearance/reverse brake clearance incorrect.
23Reverse brake return spring/retainer worn or damaged
24Needle bearing on input shaft worn or damaged.
25Thrust needle bearing on carrier worn or damaged.
Thrust washer on carrier worn or damaged.
Enoine outout low.------------------------
Flvwhcel assemblv defective.
Control lever worn or damaged.
Park pawl/park pawl shaft worn or damaged
Detent lever/park brake rod assembly worn or damaged
27
29
30
32Park gear worn or damaged.
Park pawl spring worn or damaged.
ATF strainer/ATF filter clogged.
Lower valve body assembly defective.
Lower valve bodv assemblv defective (PL regulator valve body assembly defective)'
33
34
50
Lower valve bodv assembly defective (shift valve body assembly defective).
Lower valve bodv assemblv defective (start clutch control valve body assembly defective)'
39Lower valve bodv assemblv defective {inhibitor solenoid defective}
40Solenoid harness worn or damaged.
Manual valve body worn or damaged.
PB feedback system defective.
CVT fluid deteriorated.
41
43
14-295

Road Test
NOTE: Warm up the engine to normal operating temperature (the radiator fan com6s on).
1. Apply the parking brake and block the wheels. Start the engine, then shift to the E position while depressing the
brake pedal. Depress the accelerator pedal and release it suddenly. The engine should not stall.
2. Test in E position
Park the vehicle in a slope (approx. 16'). apply the parking brake, and shift into E position. Release the brake; the
vehicle should not move.
3. Test-drive the vehicle on a flat road in the position shown in the table. Check that the engine speeds meet the approx-imate vehicle speeds shown in the table.
NOTE: Throttle position sensor voltage represents the throttle opening. To monitor the throttle position sensor volt-age, use one of the following methods:
A. Connect the Honda PGM Tester, and go to the PGM-FI Data List.
A1For road testing on '96 - 98 models, remove the drive/s side kick panel to expose the TCM; on '99 - OO models,remove the passenger's side kick panel to expose the PCM (see page l,[-236),
Set the digital multimeter to check throttle position sensor voltage between terminals:. '96 - 98 modols: TCM 84 {+} and Aa (-) or A17 (-1.. '99 - 0O models: FCM C27 {+l and 820 (-l ot 822 l-1.
DIGITAL MULTIMETER(Commerci.lly rvrilabl.lKS-AHM-32-003or oquivalant
BACKPROBE ADAPTER
BRN/BLK
A {26P1
TPS {BED/BLK}
'96 - 98 Models:
BRN/BLK
14-296
OBD ll SCAN TOOL orHONOA PGM TESTER
D{16Pt
Ware side ot female terminals
Wire side of female terminals