Counter shaft HONDA CIVIC 1999 6.G User Guide

PCM CONNECTOR B {25P)
Wire side of {emale terminals
CONNECTOR B (25P)',
*1i USA model*2: A/T (D16Y7, Dl6Yg engine)*3: CVT (D16Y5 engine)*4: M and Dl6Y7 engane*5: Except A.rT and 016Y7 engine*6: A,/T (D16Y8 engine)*7r CVT (D16Y5 engine) and D16Y8 engine*8: '96 D16Y8 engine (coupe),'97 D16Y8
models, sedan: KL model),'98 Dt6Y5
engine,'99 00 Dl6Y5 1M/Ti engine
*9: D16Y5 engine*10: M/T (D16Y5 engine)*11: Except M/T {D16YS engine}*12i D16Y5, D16Y8 engine* 13: D16Y8 engine*14: D16Y7 engine*15: '97 Dl6YTengine (coupe: KL model, sedan: KL (LX) model)''98D16Y7 engine (cont,d)engine (coupe: allengine,'98 D16Y8
FCMNOTE: Standard battery voltage is 12 v'
erminalTnumoer
Wirecotol
TerminalnameDescriptionSignal
1LS_ (LINEAR SOLENOID
VALVE - SIDE)
Ground for linear solenoid valveWii-ignnion switctr oN {ll}: pulses
2REDLS+ (LINEAR SOLENOIDVALVE + SIDE)
-Drii6l linear solenoid valveWith ignilion switch uN (lll: pulses
3BLU/YEL
SHA {SHIFT CONTROLSOLENOID VALVE A)
-Drives shift control solenoid valve AWith engine running in 2nd,3rd gears:
battery voltageWith engine running in 1st,4th gears:
about 0 V
4GRN/BLKLC B (LOCK'UP CONTROL
SOLENOID VALVE B}Drives lock up control solenoid
valve B.
With lock-up ONI battery voltage
With lock-up OFF:0 v
5YELLC A (LOCK.UP CONTROLSOLENOID VALVE A)Drives lock up controlsolenoidWith lock-uP ON: baftery voltage
With lock-up OFFi 0 V
8PNKATPD3 (NT GEAR POSI.
TION SWITCHi
Detects Py'T gear Position switch
signal.
In [D31 position: 0 V
ln ;y other position: battery voltage
1lGRN^lr'HT
SHB (SHIFT CONTROLSOLENOID VALVE B)DnGs shift conttol solenoid valve BWith engine running in 1st,2nd: battery
vo|taqeWith;ngine running in 3rd,4th: about 0 V
12WHT/REDSLU (INTERLOCK CON
TBOL UNIT)
-DlivEilite'lock control,rnit.With ignition switch ON (ll) and brake
pedal depressed: 0 V
13GRN/BLK
D4 IND (D4 INDICATORLIGHT)
Drives D4 indicator light.With Pll indicator lrght turneo urr: oarterv
voltaoeWith ld indicator light turned OFF: 0 v
14WHTNMSG {MAINSHAFTSPEED SENSOR GROUND)
GZiiI'for mainshaft speed sensol
With engine running: Pulses
In E position: 0VIn any other position: battery voltage
REDNM {MAINSHAFT SPEED
SENSOR)
Detects mainshaft speed sensor
srgnal.
ATPR {M GEAR POSI
TION SWITCH)
Detects M gear Position switch
signal
't1BLUATP2 {A/T GEAR POSITION SWITCH)
Detects A/T gear Position switch
signal.
In E position: 0VIn any other position: battery voltage
22GRNNCSG (COUNTERSHAFT
SPEED SENSOR GROUND)Ground for countershaft speed
sensor.
23BLUNC (COUNTERSHAFT
SPEED SENSOR)
Detects countershaft speed sensor
signal.
Vvith ignition switch ON (ll), and front
wheels rotating: Pulses
24YELATPD4 {M GEAF POSI-
TION SWITCH)
Detects M gear Position switch
signal.
ln E position:0 VIn any other position: 5 V
25LT GRNATPNP (A"/T GEAR POSITION SWITCH)
Detects A/T gear Position switch
srgnal,
In E orE position:0 V
In any other position: battery voltage
!a
11-89

ECM/PCM CONNECTOR O {16P)
Wire side ol temale terminalsECM/PCM CONNECTOR D {16P)
(D16Y7, D16Y8 enginelNOTE: Standard battery voltage is 12 V.
L
.1 A/J (Dl6Y7, Dr6Y8 engine)
(cont'd)
1 1-95
5i!ml
YELLCA (LOCK.UPCON]ROLSOLENOID VALVE A)Orivos look-up controlsol€noid wlv€ a.With lock-up ON: httery vollageWith lock-up OFFi 0 V
GRN,M/HT
SHB {SHIFT CONTFOLSOLENOIO VALVE B)Drivos sh ift cont.ol solanoid valv6 Bln E posnion, in 1st lnd 2nd eoat ,n E E pos'tion:Battsry voltagoInElposirion. in 3rd seat in pd, El in.th sear in
l_d polition: o v
3''GRN/BLKLC8 (IOCK UP CONTBOLSOLENOID VALVE B)Drivs locl up conttol sol€noid v6lv€ Bwhen fulllock-up: Banory vollagaWnh naf locl-uP: Pulsing si9n6l
5',BLK/YELVSSOI (BATTEsYVOLTAGEFOB SOLENOID VALVE)Powe. sourc€ ol solGnoid valvewirh ignirion sitch ON (ll): battory voltaoeWirh ignnion switch OFF:0 v
ATPR (AT GEAR POSITIONswrTcH)Detecrs Ay'T g6a. position switch signal.In any olh€r position: APProx. 10 V
8LU/YEL
SHA iSHIFI CONTROLSOLENOIDVALVE A)Oriv€6 sh ift conirol sol€noid valve A.ln tr,tr position, in 2nd €nd 3rd sear in lpd, &lposirion: Batt€ry vollsgo;n 1d soar in E, E position, in.ih se6r in E
PNKATPO3 (AT GEAR POSITIONSWITCH)Oot6cts Ay'T S6.r poeirioo switch siSnalIn Enyoth.r position: APPror, t0 v
9''YELATPD4 {AT GEAE POSITIONswrTcH)Oorocts A/I gs8r position switch signal.In any oth6t position:APProx 5 V
BIUNC (COUNTE RSHAFT SPEEDSENSOB)DetocB counr€.shaft sp66d $osr sig.alsD€p€nding on v6hicls 8pe€d;Pul.ins signalWh6n v€hicls i5 ltoPPsd:0 v
REONM (MAINSHAFTSPEED SEN.soR)O€l€cts mainshalt sp€€d 3.nsor 3ign.lsWi$ engino rLrnningl PUls6s
NMSG {MAINSHAFT SPEEOSENSOR GFOUNO)Groundfo, mainshaft sp@d sensor.
13''!T GFNATPNP {AT GEAF POSITIONswrrcH)oetscts A/T 96ar pGitaon swhch signalIn par* or n6ulral:0 VIn sny olhd po3ition: APProx l0V
BLUATPz {AT GEAE POSITIONswrTcHlDor€cis !y'T gos. posilion swilch signal.In any oth6r Position: APProx, 10 V
16''GANNCSG {COUNTEBSHAFT SPEEDSENSOE GROUND)Ground lor countershaii sp€3d s6nsor.
r lo

PGM-FI System
System Description
CKP/TDC/CYP Sensor
MAP Sensor
IAT SensorTP SensorEGR Valve Lift Sensor*'Primary H02SSecondary HO2SVSSBARO SensorELD*'KS€Starter SignalALT FR SignalAir Conditioning SignalA/T Gear Position SignalBattery Voltage {lGN.1}Erake Switch SignalPSP Switch SignalFuel Tank Pressure Sensor*iVTEC Pressure Switch*5Clutch Switch Signal*6Countershaft Speed SensornBMainshaft Speed Sensorrs
-\
----t /
F;ilrr j"-----fi-tri-'r.;l
Fb"t."'i" d" c;;il
F,h"'c;;tr*".io";-l
@."r.l"sc;;ll
EaM/PcM B""k-p F"""till
r\
-:/
Fuel IniectorsPGM-Fl Main Belay {Fuel Pump)MILIAC Valve!y'C Compressor Clutch RelayRadiator Fan Relay*,Condenser Fan RelayALT*'lcMEVAP Purge Control Solenoid
Primary HO2S HeaterSecondary H02S HeaterEGR Control Solenoid Valve*rEGR valve*6EVAP Bypass Solenoid Valve*'EVAP Control Canister Vent Shut
VTEC Solenoid Valve*5DLCLock-up Control Solenoid Valve*aShift Control Solenoid Valve*3Linear Solenoid Valve*3
*1: Dl6Y5 engine*2: USA model*3: CW (D16Y5 ensine), D16Y8 engine and 81642 ensine*4: '96 D16Y8 engine lcoupe),'97 Dl6Y7 engine (coupe: KL model, sedan: KL (LX) model),'97 D16Y8 engine {coupe: all models, sedan: KLmodel),'98-all models,'99'all models,'00-all models+5: D16Y5, D16Y8,816A2 engine*6: M/T (D16Y5 enginei*7: CVT 1D'l6Y5 engine)+8: A/T (D16Y7, D16Y8 engine)*9: '96 D16Y5 engine,'96 D16Y7 engine,'96 Dl6Y8 engine (sedan),'97 D16Y5 engine,'97 Dl6Y7 engine (coupe: KA, KC models, sedan:KA, KC, KL (LX) models, hatchback: all models),'97 D16Y8 engine (sedan: KA, KC modelsi
PGM-FI Sy3lem
The PGM-Fl system on this model is a sequential multipon fuel injection system.
Fuel iniector Timing and Duration
The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold air flow rates.
The basic discharge duration, after being read out from the memory. is further modified by signals sent from various sen-
sors to obtain the final discharge duration.
ldle Air Control
ldle Air Control Valve llAC Valve)
When the engine is cold. the A,/C compressor is on, the transmission is in gear, the brake pedal is depressed, the P/S load
is high, or the alternator is charging, the ECM/PCM controls current to the IAC Valve to maintain the correct idle speed.
lgnition Timing Control
. The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates.
lgnition timing is also adjusted for engine coolant temperature.
. Aknockcontrol system was adopted which sets the ideal ignition timing for the octane rating ofthegasoline used.*3
Othgr Control Funqtions
1. Starting Control
When the engine is started, the ECM/PCM provides a rich mixture by increasing fuel injector duration.
2. Fuel Pump Control
. When the ignition switch is initially turned on, the ECM/PCM supplies ground to the PGM-Fl main relay that sup-plies current to the fuel pump for two seconds to pressurize the fuel system.. When the engine is running, the ECI\4PCM supplies ground to the PGM-FI majn relay that supplies current to the fuel
oumo.
. When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which
cuts current to the fuel pump.
11-104
INPUTS
ENGINE CONTROL MODULE (ECMY
POWERTRAIN CONTROL MODULE (PCM) OUTPUTS

\
S40 Model (All except'99 - 00 2-door Si' SiR)
Manual Transmission
Special Tools ..'.......... 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Troubleshooting '....... 13-4
Transmission AssemblY
Removal ................. 13-5
lnstallation ............. 13-8
lllustrated Index ...............'........."........ 13-10
Transmission Housing
I Removaf .."""""""' 13-12
J R"rr"r"" Shift Holder
Clearance lnspection ....................... 13-13
Reverse ldler Gear
Removal ....'.........." 13-14
Mainshaft, Countershaft, Shift Fork
Disassembly ......'... 13-14
Mainshaft AcsemblY
Index ............... ....... 13-15
Clearance Inspection ..'.................... 13-16
Disassembly .......... 13-17
Inspection ....'......... 13-18
Reassembly ........... 13-19
Countershaft AssemblY
lndex ................ ...... 13-20
Clearance lnspection ."..........'......." 13-21
Disassembly ..."""' 13-22
Inspection .............. 13-23
Reassembly ..'.""... 13-23
Shift Fork AssemblY
lndex ............... ."'... 13-25
Clearance lnspection ."......."........'.. 13'26
MBS Shift Piece Inspection ....-.....'.. 13'27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation .......'...... ".... 13'27
Synchro Ring, Gear
Inspection '....'..".... 13'28
Shift Rod
Removal .'......".""" 13'29
Differential
lndex ......."'...... .'."' 13-30
Backlash Inspection ..........."......."... 13-30
Bearing Beplacement'.............'.".... 13'31
Final Driven Gear Replacement '..... 13-31
Thrust Shim Adiustment ..."........... 13-32
Clutch Housing Bearing
Replacement .......'. 13-34
Mainshaft Thrust Shim
Adiustment '....'..".. 13-36
Transmission
Reassembly ........... 13-39
Oil Seals
Replacement ......... 13-43
Gearshift Mechanism
Overhaul ................ 13-44
\

Torque Value
A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft)
B - 27 N.m (2.8 kgf.m. 20 lbift)
C - 31 N.m {3.2 kgnm, 23 lbift)
\
O BALL BEARING (*T)
ANGULAR
BALL BEARING {*2I
O 5TH SYNCHRO HUB
O 5TH SYNCHRO SLEEVE
€) SYNCHRO SPRING
o SYNCHRO B|NG
@ 5TH GEAR
@ gz xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@34x39x23mm
NEEDLE BEARING
(D 4TH GEAR
O SYNCHRO RING
C) SYNCHRO SPRING
CO 3RD/4TH SYNCHRO SLEEVE
@ 3RD/4TH SYNCHRO HUB
(} 3RD GEAR
@34x39x27.5mmNEEDLE BEARING
G) MAINSHAFT
G) WASHER
@ SPRING WASHER
@ BALL BEARING
Check for wear and
operation.(E 26x42x7 mm OIL SEAL
Replace.
@ 28 mm PLUG BOLT
5,1 N.m {5.5 kgf'm, /t0 lbt'ft)
@ lsT/zND SELECT SPRING
L. 36.26 mm (1./P8 in)
@ SHIFT ARM SHAFT
@ CLUTCH HOUSING
@ INTEELOCK GUIDE BOLT
39 N.m (4.0 kgf.m, 29 lbf.ftl
@ REVERSE SHIFT HOLDER
@ REVERSE IDLER GEAR
@ REVERSE IDLER GEAR SHAFT
@ 5 x 22 mm SPRING PIN
Replace.
@ 3RD/4TH SHIFT PIECE
@ 5TH/REVERSE SHIFT PIECE
@ MBS SHIFT PIECE
@ 1ST/2ND SHIFI FORK
*1:D16Y7 engine*2: D16Y5, D16Y8 engines
@ 3RD//|TH SHIFT FORK
@ 5TH/REVERSE SHIFT FORK
@ 52 mm SNAP RING
@ 65 mm THRUST SHIM (*11
70 mm THRUST SHIM (*21
Selection, page 13-36
@ OIL GUIDE PLATE
@ wASHER Replace.
@ BACK.UP LIGHT SWITCH
25 N.m (2.5 kgf'm, 18 lbf'ft)
@ sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@ WASHER Replace.
@D SPRING 1.31.6 mm (1.2,1inl
@ STEEL BALL 15/16 in)
@ BACK-UP LIGHT
SWITCH HARNESS BRACKET
@ TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m (2.5 kgf.m, 18 lbt'ft)
@ OIL SEAL
Replace.
@ OIL DRAIN PLUG
39 N.m (4.0 kgf.m, 29 lbf.ft)
@ WASHER Replace.
@} OIL FILLER PLUG
44 N.m (4.5 kgf.m, 33 lbf'ftl
@ WASHER Replace.
@) TRANSMISSION HOUSING
€) CLUTCH LINE BRACKET
@ OIL GUTTER PLATE
@ REVERSE LOCK CAM
@ REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@ REVERSE SELECT RETAINER
@ SHIFT ARM C
@ SHIFT ARM B
@ INTERLoCK
@ COLLAR
@ SHIFT ARM A
@ SPRING WASHER
@ MAGNET
@ sET BALL SPRING BOLT
22 N.m (2.2 kgf.m, 16 lbf.ftl
@ 14 x 20 mm DOWEL PIN
@ 72 mm THRUST SHIM l*11
80 mm THRUST SHIM (*21
Selection, page '13-33
@ DIFFERENTIAL ASSEMBLY
See page 13-30
@ 14 x 25 x 17.5 mm OIL SEAL
Replace.
@ 35 x 56 x 8 mm OIL SEAL
Replace.
@ SHIFT ROD
@ BOOr
@ OIL GUIDE PLATE
@30x47x21 mm
NEEDLE BEARING (* 1}
30x55x21 mm
NEEDLE BEARING {'2)
@ COUNTERSHAFT
@36x41 x 25.5 mm
NEEDLE BEARING
Check for wear and
operatron.
@ lsT GEAR
@ FRICTION DAMPER
@ SYNCHRO RING
@ SYNCHRO SPRTNG
@ lST/2ND SYNCHRO HUB
@ REVERSE GEAR
@ SYNCHRO SPRING
@ SYNCHRO RING
@ FRICTION DAMPER
@ SPACER
@39x4lx27mm
NEEDLE BEARING
@ 2ND GEAR
@ 3RD GEAR
@ 4TH GEAR
@ sTH GEAR
@) BALL BEARING {* 1}
NEEDLE BEARING (*2}
@ BALL BEARING
@) SPRING WASHER
@ LoCKNUT Replace.
108 - 0- 108 N.m
ftt.o* o- 1r.o kst.m,l
179.6- 0- 79.6 rbtft I

13-1 1

Transmission Housing
Removal
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the back-up light switch.
2. Remove transmission hanger.
TRANSMISSIONHANGER
BACK-UP LIGHT SWITCH
Remove the setting screws. washers. springs, and
steel balls.
STEEL BALLSO. 5/16 in
SPRINGL. 31.6 mm I 1.24 inl
13-12
SETTING SCREW
TRANSMISSION HOUSING
6.
4.Loosen the transmission housing attaching bolts in
a crisscross pattern in several steps, then remove
them.
Remove the 32 mm sealing bolt.
Expand the snap ring on the countershaft ball bear-
ing, and remove it from the groove using a pair of
snap ring pliers.
32 mm SEALING EOLT
Separate the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the thrust shim, oil guide plate. and oil gut-
ter plate from the transmission housing.
(o
7.
otLGUTTERTE
SNAP RING

Reverse ldler Gear
Mainshaft, Cou ntershaft,
Shift Fork
Removal
1. Remove the reverse shift holder.
REVERSE SHIFTHOLOER
Remove the reverse id ler
idler gear.
gear shaft and reverse
REVERSE IDLERGEAR SHAFT
13-14
Disassembly
1. Remove the interlock guide bolt from under the
clutch housing.
SHIFT ARM 8ATTACHING BOLT
CLUTCHHOUSING
INTERLOCK GUIDE BOLT
Remove the shift arm B attaching bolt.
Remove the mainshaft and countershaft assemblies
with the shift fork from the clutch housinq.
NOTE: Before removing the mainshaft and counter-
shaft assemblies, tape the mainshaft splines to pro-
tect the seal.
Tape the mainshaftsplines.
WASHER
SPRINGWASHER

Countershaft Assembly
Index
I.r
NOTE:
-re
The 3rd, 4th, and sth gears are installed with a press.
Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the3rd, 4th, and 5th gears.
Snap ring groove faces up.
LOCKNUT Replace.108-O- 108 N.m
I 11.0-O-11.0 kst.ml
I 79.6-0- 79.6 lbt.ft I
SYNCHRO SPRING
SYNCHRO RINGInspectaon, page 13-28
FRICTION DAMPER
Thin edge ol outerrace faces down.
Check for wear andoperatron,
/ BALL EEAR|NG t*1)
t NEEDLE BEARTNG (.2)
Check for wearand operatron,
WASHERBEARING
GEAR
4TH GEAR
3RD GEAR2ND GEAR
FRICTION DAMPER
SYNCHRO SPRING
SYNCHRO RINGInspection, page 13-2836 x 41 x 25.5 mmNEEDLE BEARINGCheck for wear and operataon.
Inspection, page 13-23
1ST GEARlnspection, page 13 21, 28lnspection, page 13-21, 2839x44x27mmNEEDLE BEARIfI'GCheck for wear andoperation.
SPACER COLLARInspection, page 13-21
REVERSE GEARlnspection, page 13 27
1ST/2ND SYNCHRO HUB
*1: D'16Y7 engine*2: D16Y5, D16Y8 engines
13-20

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

Countershaft Assembly
Disassembly
CAUTION: Remove the gears using a press and steelblocks as shown. Use of a iaw-type puller can damagethe gear teeth.
1. Securely clamp the countershaft assembly in a
bench vise with wood blocks.
2. Raise the locknut tab from the groove of the coun-
tershaft, then remove the locknut and the springwasher.
3.Remove the bearings using a bearing puller as
shown.
EEARING PULLER
\
4. Support 4th gear on steel blocks, and press the coun-tershaft out of 5th and 4th gears as shown.
Support 1st gear on steel blocks, and press the coun-
tershaft out of 3rd gear as shown.
5.
I./
3RD GEAR
1ST GEAR