Body HONDA CIVIC 1999 6.G Workshop Manual

Continuously Variable Transmission (CVTI
Special Tools ................ 14-194
Description .................... 14-195
Clutches/Reverse Brake/Planetary
Gear/Pulleys .......... 14-198
power Flow ..............,..... 14-200
Electronic Control SYstem(,96 - 98 Modets) ......14-203
Electronic Control System
('99 - oo Models) " 14-205
Hydraulic Control '....... 14-208
Hydraulic Flow .'..-.....'... '14-212
Park Mechanism .....-...'.' 14-222
Eleqtrical Systom
Component Locations'96 - 98 Models """"""' 14-224,99 - 00 Modets ............. 14-225
TCM Circuit Diagram ('96 - 98 Models) ............. 14-226
TCM Terminal Voltage/Measuring Condiiions ('96 - 98 Models) '.... 14-228
PcM Circuit Oiaqram{A/T Control System: '99 - 00 Models} ...--.... 14-230
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)
A/4 Control System .'.'...14-232
Troubleshooting Procedures ... . .... .....',........."' '14-234
Symptom-to-ComPonent Chart
Electrical System - '96 - 98 Models ......'..... '14-234
Electrical System -'99 - 00 Models ..'....-..-. '11-210
Electrical Troubleshooting
Troubleshooting Flowcharts('96 - 98 Models) """'11-242
Troubleshooting Flowchart
('99 - 0O Modets) ...... 14-265
Linear Solenoids/lnhibitor Solenoid
Test ......................... . ...... 14-29f
Drive Pulley/Driven Pulley/Secondary Gear
Shaft Speed Sensors
Replacement .........'...... .14-292
Start Clutch Control
Start Clutch Calibration Procedure ....... ....,. 14-293
Hydraulic SYstem
Symptom-to-ComPonent Chart
Hydraulic System '.'.......14-294
Road Test ............................ 14-296
Stall Speed
Test......................... ...... 14-294
Fluid Level
Checking/Changing ....... 14-299
Pressure Testing ................. 14-300
Lower Valve BodY AssemblY
Replacement ..........,... 14-302
ATF Filter
Removal/lnstallation ..... 14-303
Transmission
Transmission
Removal ........... . 14-304
lllustrated Index
Transmission/Lower Valve BodY
Assembly ................. 14-308
Transmission Housing/Flywheel Housing ... 14-310
End Cover/f ntermediate Housing ..........'.'.... 14-312
Transmission Housing/Lower Valve Body Assembly
Removal ..........'.... .. " 14-314
Transmission Housing/Flywhesl Housing
Removal ................. ........ 1+316
End Cover/lntermediate Housing
14-318Removal .........,...............
Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'..... 1 4-320
Forward Clutch
lltustrated Index ........................................ 14-321
Disassemblv .................. 14-322
Reassemblv , ,, . ',','......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection ..'.'....-... 14-324
Differential
lllustrated lndex ...,.....................,.,...-.-.-...'... 14-329
Backlash Inspection .-....14-329
Bearing Replacement ......'........'....'... ....'... 14-330
Differential Carrier Replacement ........'........ 14-330
Oil Seal Removal ........... 14-331
Oil Seal Installation/Side Clearance ....... . . 14-331
Flywheel Housing Input Shaft Oil Seal
Replacement .....,.... ...'.'.. 14-333
Transmission Housing Bearings
Driven Pulley Shaft Bearing
Replacenient ...................'. . ...................'.. 14-334
Secondary Gear Shaft Bearing
Reolacbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Secondary Gear Shaft BearingReo1acement..................,........................... 14-335
Ring Gear Bearing
Replacement......... ........ 14-336
Control Shaft Assembly
Removal/lnstallation ....................'........... 14-336
Transmission
Reassembly .................. 14-338
Flywheel/Drive Plate .. . ...... . ...... ... . ....-.....'.'...14-341
Transmission
lnstalation ..................... 14-348
Cooler Flushing .'......... 14-352
shift cable
Removal/lnstallation....'........." """ 14-354
Adjustment .......'........ 14-355
Shift Lever ........................,. 14'356
Shift Indicator Panel
Adjustment ................ 14-357
ATF Cooler/Hoses
lnsta llation ......,,...... .... 14-357

Description
The Continuously Variable Transmission (CVT) is an electronically controlled automatic transmission with drive and driv
en Oullevs, and a steel belt. The CVT provides non stage speeds forward and one reverse. The entire unit is positioned in
line with the engine.
Transmission
Around the outside of the flywheel is a ring gear which meshes with the starter pinion when the engine is being staned.
The transmission has four parallel shafts: the input shaft, the drive pulley shaft. the driven pulley shaft, and the secondary
gear shaft. The input shaft is in line with the engine crankshaft. The drive pulley shaft and the driven pulley shaft consist of
movable and fixed face pulleys. Both pulleys are linked by the steel belt.
The input shaft includes the sun gear. The drive pulley shaft includes the forward clutch which mounts the carrier assem-
bly on the forward clutch drum. The carrier assembly includes the pinion gears which mesh with the sun gear and the ring
gear. The ring gear has a hub-mounted reverse brake disc.
The driven pulley shaft includes the start clutch and the secondary drive gear which is integral with the park gear' The sec-
ondary gear shaft is positioned between the secondary drive gear and the final driven gear. The secondary gear shaft
includes the secondary driven gear which serves to change the rotation direction. because the drive pulley shaft and the
driven oullev shaft rotate the same direction. When certain combinations of planetary gears in the transmission are
engaged by the clutches and the reverse brake, power is transmitted from the drive pulley shaft to the driven pulley shaft
to provide E, E, E, and El.
Electronic Control'96 - 98 Models:
The electronic control system consists of the Transmission Control Module (TCM), sensors, three linear solenoids, and a
inhibitor solenoid. Shifting is electronically controlled under all conditions'
The TCM is located below the dashboard, behind the kick panel on the driver's side.'99 - 00 Models:
The electronic control svstem consists of a Powertrain Control Module (PCM), sensors, three linear solenoids and an
inhibitor solenoid. Shifting is electronically controlled under all conditions. A Grade Logic Control System to control shift-
ing in E position while the vehicle is ascending or descending a slope.
The PCM is located below the dashboard, under the kick panel on the passenger's side.
Hydraulic Control
The lower valve body assembly includes the main valve body, the Pressure Low (PL) reguiator valve body, the shift valve
body, the start clutch control valve body, and the secondary valve body. They are positioned on the lower part of the
transmission housing.
The main valve body contains the Pressure High (PH) control valve, the lubrication valve, and the pitot regulator valve.
The secondary valve body contains the PH regulator valve, the clutch reducing valve, the start clutch valve accumulator,
and the shift inhibitor valve. The PL regulator valve body contains the PL regulator valve and the PH-PL control valve
which is ioined to the PH,PL control linear solenoid. The inhibitor solenoid valve is bolted on the PL regulator valve body.
The shift valve body contains the shift valve and the shift control valve. which is joined to the shift control linear solenoid.
The start clutch control valve body contains the start clutch control valve, which is joined to the start clutch control linear
solenoid. The linear solenoids and the inhibitor solenoid are controlled by the TCM or PCM. The manual valve body which
contains the manual valve and the reverse inhibitor valve, is bolted on the intermediate housing.
The ATF pump assembly is located on the transmission housing, and is linked with the input shaft by the sprockets and
the sprocket chain. The pulleys and the clutch receive fluid from their respective feed pipes, and the reverse brake receives
fluid from internal hydraulic circuit.
Shift Control Mechanism
Input from various sensors located throughout the vehicle determines which linear solenoid the TCM or PCM will activate.
Activating the shift control linear solenoid changes the shift control valve pressure, causing the shift valve to move. This
pressurizes the drive pulley pressure to the drive pulley and the driven pulley pressure to the driven pulley and changes
their effective pulley ratio. Activating the start clutch control linear solenoid moves the start clutch control valve. The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it(cont'd)
14-195
,!

Description
Hydraulic Control
The hydraulic control system is controlled by the ATF pump. the valves, and the solenoids. The ATF pump is driven by theinput shaft. The ATF pump and the input shaft are linked by the ATF pump drive chain and the sprockets, The inhibitorsolenoid valve and the linear solenoids. which are located on their valve body, are controlled by the TCM or pcM. Fluidfrom the ATF pump flows through the PH regulator valve to maintain specified pressure to the drive pulley, the driven pul-ley, and the manual valve,
The lower valve body assembly includes the main valve body, the PL regulator valve body, the shift valve body, the startclutch control valve body, and the secondary valve bodv.
Main Valve Eody
The main valve body contains the pH control valve, the rubrication valve, and the pitot regulator valve.
PH Control Valve
The PH control valve supplies PH control pressure (PHCI in accordance with the pH-pL control pressure (HLc), and sup-plies PH control pressure to the PH regulator valve, which also regulatss PH pressure. At kick-down, it increases pHcontrol pressure which increases the high (PH) pressure. This shortens the shift speed by releasing the reverse inhibitorpressure (Rl)from the inhibitor solenoid valve.
Lubrication Valve
The lubrication valve controls the lubrication pressure to each shaft and maintains lubrication pressure. When rne pres-sure is too high, the spring is compressed. This moves the lubrication valve and opens the fluid leak passage.
Pitot Regulalor Valv6
The pitot regulator valve controls the start clutch pressure (SC) in accordance with the engine speed, when the electron-ic control system is faulw.
MAIN VAIVEBODY
L.
14-208

Secondary Valve Body
The secondary valve body contains the PH regulator valve. the clutch reducing valve' the start clutch valve accumulator'
and the shift inhibitor valve
PH Regulator Valve
The pi regulator valve maintains hydraulic pressure supplied from the ATF pump. and supplies PH pressure to the
hvdraulic control circuit and the lubrication circuit. PH pressure is regulated at the PH regulator valve by the PH control
pressure (PHC) from the PH control valve.
Cluteh Reducing Valvo
The clutch reducing valve receives PH pressure from the PH regulator valve and regulates the clutch reducing pressure
(cR). The clutch reducing valve supplies clutch pressure (cR) to the manual valve and the start clutch control valve' and
supplies signal pressure to the PH-PL pressure control valve. the shift control valve, and the inhibitor solenoid valve'
Start Clutch Valv€ Accumulator
The start clutch vatve accumutator stabilizes the hydraulic pressure that is supplied to the start clutch'
Shift Inhibitor Valve
The shift inhibitor valve switches the fluid passage to switch the start clutch control from electronic control to hydraulic
control when the electronic control system is faulty. lt also suppliss clutch reducing pressure (cR) to the pitot regulator
valve and the pitot lubrication pipe.
START CLUTCH VALVE
SECONDARY VALVEBODY
SHIFT INHIBITOE VALVE
(cont'd)
PH REGULATOR VAL
REDUCING VALVE
14-209

Description
Hydraulic Control {cont'dl
PL Regulator Valve Body
The PL regulator valve body contains the PL regulator valve and the PH-PL control valve. which is joined wirh the pH-pL
control linear solenoid. The inhibitor solenoid is bolted on the pL regulator valve body.
. PL Regulator Valve
The PL regulator valve supplies low p.essure (pL) to the pulley to eliminate steel belt slippage.The PL pressure is controlled by the pH-pL control pressure (HLC).
. PH-PL Control Valve
The PH-PL control valve controls the PL regulator valve according to engine torque. The PH-PL control valve suooliesPH-PL control pressure (HLC) to the PH control valve to regulate PH pressure higher than pL pressure. The pH-pL con-trol valve is controlled by the PH-PL control linear solenoid. which is controlled by the TcM or pcM,
. Inhibitor Solenoid
The inhibitor solenoid controls the reverse inhibitor valve by turning on and off. Also, the inhibitor solenoad controls pH
control pressure (PHC) by applying reverse inhibitor pressure (Rl) to the PH control valve. The inhibitor solenoid is con-trolled by the TCM or Pclvl.
Start Clutch Control Valv€ Body
The start clutch control valve body contains the start clutch control valve. Both are joined to the stan clutch control linearsolenoid.
. Start Clutch Control Valve
The start clutch control valve controls start clutch engagement according to the throttle opening. The start clutch con,trol valve is controlled by the stan clutch control linear solenoid, which is controlled bv the TCM o. pCM.
START CLUTCH CONTROLvAt-vE
LOWER VALVE BODYASSEMBI-Y
PH.PL CONTROLLINEAR SOLENOID
I.
14-210

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

Electrical Troubleshooting (,96 - 9g Modelsl
Troubleshooting Flowchart - Shift Control Linear Solenoid
Possible Cause
' Disconnected 3olenoid h.rn€isconnoctor. Short or open in 3hift controllinear solenoid wire. Faulty shift control linear sole-noidSOLENOID HARNESS8P CONNECTOR
Terminal stde of male terminals
Wire side of female terminals
8LU/YEL
NOTE: Record all freeze data before you troubleshoot.
. OBD ll Scan Toot indicates CodeP1870.. Selt-dirgnosis [d indic.tor tightindicatos Code 30.
Measure Shift Control Linoar Sole-noid Resistance at the SolenoidHarness Connector:1. Disconnect the 8p connectorfrom the solenoid harness connector.2, Measu re the resistancebetlveen the No. 3 and the No.7 terminals ofthe solenoid haFness connector.
ls the resistance 3.8 - 6.8 O?
Check Shift Controt Linear Sote-noid for a Short Circuit:1. Disconnect the A (26p) con,nector from the TCM.2. Check for continuity betweenbody ground and the A3 terminal and the A16 terminalindividually.
Repair shon in tho wire6 betweonthe A3 and A16 termin.ts lnd thobody ground.
Measure Shitt Control Line.rSolenoid Resistance:1. Connect the 8P connector tothe solenoid harness connec,tor.2, Meas u re the resistancebetween the 43 and A16 ter-
Repair loose terminal oa open inthe wires between the 43 andA16 terminal3 and the solenoidharness connector.
ls the resistance 3.8 6.8 O?
Chock for loose TCM connectorc.ll necessary, substitute a known-good TCM and recheck.
BLU/WHT
GRN/YEL
TCM CONNECTOR A I26PI
GRN/YEL
ll 12l:
IriGlx
1578910111213
172t)232526
14-250

Troub|eshootingF|owchart_PH-PLControJLinearSo|enoid
NOTE| Record all treeze data before you troubleshoot
Possible cause
' Disconnected solenoid harness
connectof. Short or oPen in PH_PL control
linear solenoid wire. Faulty PH-PL control linear sole_
noidSOLENOIO HARNESS8P CONNECTOR
GRN/WHT
Terminal side of male termlnals
Wire side ol female terminals
. OBD ll Scan Tool indicates Codo
P1873.. sef-diagnosis E indicalor light
indicat6 Code 31.
Measure PH-PL Control Linear
Solenoid Resistance at the Sole_
noid Hatness Connectot:1. Disconnect the 8P connector
from the solenoid harness con-
nector,2. Measure the resistance
between the No 2 and the No.
6 terminals ofthe solenoid har
ness connector'
ls the resistance 3.8 - 6.8 0?
Check PH-PL Control Lineer
Solenoid for a Short Circuit:
1. Disconnect the A 126P) con-
nector lrom the TCM
2. Check for continuity between
body ground and the A2 ter
minal and the A15 terminal
individually.
Repair short in th€ wires
between the A2 and A15 lermi_
nals and the body glound.
Measute PH-PL Control Linear
Solenoid Resi3tance:1. Connect the 8P connector to
the solenoid harness connec-
tor,2, Meas u re the reslslance
between the ,q2 and A15 ter_
Rep.il loose tetminal or oPen in
th6 wires betwccn the A2 and
A15 lerminals and the solenoid
harness conn€ctol.
lsthe resistance 3.8-6 8 O?
Check for loose TCM connactors
lf neceasery, Substitute a known-good TCM and rechock.
PNK/BLK
TCM CONNECTOR A (26P)
oPNK/BLK
I234578I10l11213
11't5161720/,,/232526
IGRN/wHr
o
*r}l
t'T,
E[
PNK/8LK
3a5I910111213
1620232526
GRN/WHT
14-251

Electrical Troubleshooting ('96 - gg Modelsl
Troubleshooting Flowchart - start clutch control Linear solenoid
NOTE: Record all freeze data before you t.oubleshoot.
Po$iblo C.u.o
' Di3aonnoctod solanoid harncatconnactol. Short or opon in start clutchcontrol linoar tolanoid wira. Faulty ttart clutch control lino.rsolanoid
SOLENOID HARNESS8P CONNECTOR
Terminal side of male terminals
Wire side of female terminals
. OBO ll Scan Tool indicatG CodeP1879.. Self-dilgno.is E indicator lightindiclt$ Code 32.
Me.suro Sta.t Clutch ControlLinear Solenoid Rosirtrnco st th.Solenoid Hrrn6rs Connecto.:1. Disconnect the 8P connectorfrom the solenoid harness con-nector.2, Measure the resistancebetween the No. 4 and the No.8 terminals otthe solenoid har-ness connectot.
ls the resistance 3.8 - 6.8 0?
Chock Start Clutch Control Lin-oar Solenoid tor a Short Circuit:1. Disconnect the A (26p) con,nector from the TcM.2. Check lor continuity betweenbody ground and the A1 ter-rninal and lhe Al il terminalindividually.
Raprir 3hort in tha wira3b.ftvcen tho A1 .nd Atil t .mi.n.l. .nd thr body ground.
Measure Stan Clutch Cont.olLineer Solenoid F6aist.ncei1. Connect the 8P connector tothe solenoid harness connec-tor.2. Meas u re the resistancebetween the 41 and Al4 ter-minals,
Rcplir loose tcrminal or oDcn inthG wiras b.tween the Al rndAla torminal3 rnd tha 3olanoidhamaas connactor.
ls the resistance 3.8- 6.8 O?
Check for loose TCM connecto.s.lf necessary, substitute a known-good TCM and iecheck.
YEL
PNK/BLU
TCM CONNECTOR A I26P}
-{r-
E
PNK/BLU
23a51I910ll1213
a15t61'20a252G
YEL
14-252

Troubleshooting Flowchart - Inhibitor Solenoid
NOTE: Record all treeze data betore you troubleshoot
Po$ibls Cause
. Dbconnected solenoid hatness
connedor' Short or opon in inhibitor sole'
noid wire. Faultv inhibitor solenoid
SOLENOID HARNESS8P CONNECTOR
Terminal side of male terminals
. OBD ll Scan Tool indic.td Code
P1882.. Selt-di.gnGis E indicator lighl
indic.tos Code 33.
Mea3ure Inhibhor Solenoid Resid-
ance at the sol€noid Harness
Connector:1. Disconnect the 8P connector
from the solenoid harness
connector.2. Measure the reslstance
betlveen the No 5 terminal of
the solenoid harness connec-
tor and body ground.
ls the resistance 11.7 - 21 0 0?
Check Inhibitor Solenoid lor a
Short Circuii:1. Disconnect the B (22P) con-
nector from the TCM.
2. Check for continuity between
the B1 terminal and bodygro!no.
Repair rhort in the wire ltetwegn
the 81 dnd the bodY ground.
Mea$rr€ Inhibitor Solenoid ResBt'
anoe:1. Connect the 8P connector to
the solenoid harness connec_
IOr.2. Measure the resistance
between the Bl and bodyground.
Reoair loose terminal or open in
the wire betwean the 81 and the
solenoid hame3s connector'ls the resistance 11.7 - 21.0 O?
Ch6ck for loose TCM connectors.
ll necessary, substhule a known_good TCM and techeck.
Wire side of female terminals
14-253