CABLE HONDA CIVIC 1999 6.G Service Manual

Shift Cable
Adjustment
@ Make sure lifts are ptaced properly (see
section 1).
1. Remove the front console (see section Z0l.
2. Shift to @ position. then remove the lock pin fromthe adiuster.
7 N.m (0.75 tbtftlkgtm.
14-190
3. Check that the hole in the adjuster is perfectlyaligned with the hole in the shift cable. There aretwo holes in the adjuster. They are positioned 90.apart to allow cable adjustment in 1/4 turn incre-ments.
ExactAlignment
4. lf the hole is not perfectly aligned, loosen the lock-nut on the adjuster and adjust as required.
5. Tighten the tocknut to 7 N.m (0.7 kgf.m, 5 tbf.ft).
6. Install the lock pin on the adjuster. lf you feel thelock pin binding as you reinstall it, the cable is stillout of adjustment and must be readjusted.
7. Make sure the lock pin is seated in the adjustersecuretv.
8. Move the shift lever to each gear, and verify that theshift position indicator follows the automatic trans-axle gear position switch.
9. Start the engine, and check the shift lever in allgears. lf any gear does not work properly, refer totroubleshooting (see page 14-109 thru 1'4-'112).
10. Insert the ignition key into the key cylinder on theAy'T gear position indicator panel, and verify that theshift lock lever is released.
CableToo ShortCableToo Long

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

Symptom-to-Component Chart
Hydraulic System
*1: Some gear noise is normal in the Lll position due to planetary gear action.
14-294
SYMPTOMCheck these items on the PBOBABLE CAUSE List
Engine runs, but vehicle does not move in any position.'t,2,3,4,5,6,7,8,9, 10, 20, 34, 35, 36, 38, 41
Vehicle does not move in @, [. p positions.10,11, 12, 20, 41
Vehicle does not move in E position.5, 'to, 11, 12, 17, 1A, 19, 20,39, 41
No shift to higher ratio,9, 13, 14. 15, 16,35,37,40
Poor acceleration.9, 13,'t4,'t5,16. 20, 35, 37, 38, 40
Flares on moving.9,'t0, 20, 2't, 35, 36, 38, 40, 42
Excessive shock when depressing and releasing.^^alA/.r^r ^A.1. I9, 10, 20, 2'1, 35, 36, 3A, 42
No engine braking.9,20,21,35,36,38
Vehicle does not accelerate in lll position.9, 17, 18, 19, 20. 35, 36, 38
Vehicle moves in E position.
(Shift cable adjustment is proper).10, 22,23
Late shift from N position to E position, and from Eposition to E position.'10,11, 12,22, 41
Late shift from E position to E position. and from Eposition to N position.1l,'t2, 17, 18,22, 41
Engine stops when shifted to E position from E position.9, 10,20,35,37,34, 42
Engine stops when shifted to E position from I position.9, 18, 19,20,25,26,35,37,38, 42
Noise from transmission in @ position.rl5, 17, 18, 't9,25,26
Excessive idle vibration.2,3,4,21,24
Noise from transmission in @ and @ positions.2,3, 19,24,25,2A
Hunting engine speed.16, 35, 37, 38
Vibration in all position.8, 2a
Shift lever does not operate smoothly.11,29, 4'l
Transmission will not shift into lll position or transmis-
sion cannot be removed from E position.11 , 29, 30, 31, 32,33
Vehicle does not accelerate to more than a certain speed.9, 10, 14, 15,'t6,20,35,37
Excessive shock on starting off.38, 42
Flares on accelerating at low speed.20, 21 ,38, 42
Excessive vibration in E, E, tr, E positions.20,21,38, 42
Low engine speed in E. E. tr. E positions.20,21,38,42
Stall speed high.10,20,38
Stall speed low.9, 20, 27 ,37 , 38
Judder on starting off.20, 43

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

Transmission
Removal
@. Mako suro lifts. iacks, and satety stands are placod
properly, and hoi3t bracket are attached to lhe cor-
rect position on the engine {see soction 1}.
. Apply parking brake and block r€ar wheels so tha
vehicle will not roll off stands and fall on you while
working undor it.
CAUTION: Use tender covers to avoid damaging painted
surfaces.
Disconnect the battery negative (-) terminal from
the battery, then remove the positive (+)terminal.
Remove the intake air duct and air cleaner housing
1.
assembly.
3. Remove the starter cables and cable holder from
the starter motor.
STARTER CABLE
STARTER MOTOR
14-304
4, Disconnect the solenoid harness connector, the drivepulley speed sensor connector, and the ground cable
terminals.
DRIVE PULI.-EYSPEED SENSORCONNECTOR
SOLENOIO HARNESSCONNECTOR
Remove the clip, then separate the shift cable from
the control lever,
CAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
GROUND CAELE
CONTROL LEVER
S}IIFT CABLE

6) TRANSMISSION HOUSING GASKET Replace'
@ DOWEL PIN
@) ATF FEED PIPE
@ o-RING Replace.
60 o-RING Replace.
@) DRIVE PULLEY SPEED SENSOR
@ TRANSMISSION HANGER
@ SNAP RING
@ txaust Sxtfu, zs t 31 mm selective part
@ SALL BEARING
6J RING GEAR6D SNAP RING
@ aevense aRlxe rND PLATE Selective part
@ REVERSE BRAKE DISC
@ REVERSE BRAKE PLATE
@ DISC SPRING6} THNUST WASHER
@} finusr NeeoLr eelnNc
@ THRUST WASHER
@ GARRIER ASSEMBLY
@ THRUST WASHER
@ THRUST NEEDLE BEARING
@} SUN GEAR
@ SEALING RING REPIACE'
@ NEEDLE BEARING
@ INPUT SHAFT
@ NEEDLE BEARING
@ SEALING RING FEPIACE'
@ SEALING RING {RUBBERI Replace'
@ ATF FEED PIPE
O END COVER
O ATF FEED PIPE
O DOWEL PIN
@ O-RING Replace.G) FEED PIPE FLANGE
@ reeo ppe ruruce puru
O] ROLLERO IruTENMEDNTE XOUSING ASSEMBLY
ao corutnoL sxlrr lsseugLv
@ tnlrusmtsstottt ttoustt'tc
@ SHIFT CABLE BRACKET
c) BREATHER CAP
@ oll- SEAL Replace.
@ CONTROL LEVER
G LoCK WASHER Replace.(D secololaY ceaR SHAFT SPEED sENsoR
o) onvel put-uv sPEED SENSOR
@ O-RING Replace.(O SNAP RING6 rnmrsutsstoru xouslNc oRlvEN PULLEY
SHAFT ROLLER BEARING
@ END COVER GASKET REPIACE'
@ o-RING Replace
6o mnruulL vnLVe goDY LINE A
64 MANUAL VALVE BODY LINE B
@ O-RING Replace.
@ DETENT SPRING
O ATF FEED PIPE
@ O-RING Replace.
@ MANUAL VALVE EODY
@ DOWEL PIN
@ r'rllull valve goDY SEPARAToR PLATE
6D SNAP RING
@t roRwlno cturcx ASSEMBLY
@ o-RING Replace
@ SNAP RINGo3 spnlruc aetlrupn/RETURN SPRING ASSEMBLY
@ nevense ennr eBtottt
@ o-RING Feplace.
@ SNAP RING RE'AINER
@ ATF FEED PIPE
.1,
TOROUE SPECIFICATIONS
6x1.0mm
6x1.0mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.25 mm
12 N.m (1.2 kgf'm,8.7 lbf'ft)
14 N.m {1.4 kgf'm, 10 lbift)
37 N.m (3.8 kgf'm, 27 lbf'ft)
26 N.m (2.7 kgf'm,20 lbf'ft)
29 N.m (3.0 kgf'm, 22 lbf'ft)
6B
8B
8F
8G
14-313
rl,

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

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)

t
Adjustment
!@ Make sure lifts, jacks and safety stands are
placed properly (see section 1).
l. Remove the front console (see section 20).
2. Shift to I posirion, then remove the lock pin from
the adjuster.
SHIFT CAELE
l,
,l
{0.7 kgf.m, 5lbf'ltl
3. Check that the hole in the adiuster is perfectly aligned
with the hole in the shift cable. There are two holes in
the adjuster. They are positioned 90" apart to allow
cable adjustment in 1/4 turn increments.
lf the hole is not perfectly aligned, loosen the lock-
nut on the adjuster and adjust as required.
Tighten rhe locknut to 7 N.m (0.7 kgim,5 lbf'ft).
Install the lock pin on the adjuster' lf you feel the
lock pin binding as you reinstall it. the cable is still
out of adjustment and must be readjusted
Make sure the lock pin is seated in the adiuster
securery.
lMove the shift lever to each position, and verify that
the shift position indicator follows the automatlc
transaxle gear position switch.
Start the engine, and check the shift lever in all
positions. lf any gear does not work properly, refer
to troubleshooting (see page 14-294 and 14-295).
Insert the ignition key into the key cylinder on the
Aff gear position indicator panel, and verify that the
shift lock lever is released.
7.
10.
14-355

Driveshafts
Disassembly (cont'dl
4. Mark the rollers and spider to identify the locations
of the rollers on the sDider, then remove the rollers.
B€ARING REMOVER{Commerciallv available}
STOP RING(Applicable to '96 - 98 modols andErazil-produced driveshafts)
Remove the circlip.
Mark the spider and driveshaft to identify the posi-
tion ot the spider on the shaft.
Remove the spider using a bearing remover.
Remove the stop ring (Applicable to '96 - 98 models
and Brazil-produced driveshafts).
Wrap the splines on the drivsshaft with vinyl tape to
prevent damage to the boot and dynamic damper.
DRIVESHAFT
1.
VINYL TAPE
DYNAMIC DAMPERCheck for damage.
Remove the inboard
dynamic damper.
INBOARO AOOTInspect for cracking,splitting and wear.
16-6
boot, and if necessary, the
Outboard Joint Side:
1. Lift up thc three tabs with a screwdriver, then
remove the boot bands, Take care not to damage
the boot.
NOTE:
. lf the boot band is a double loop type, lift up the
band bend.
. lf the boot band is a welded type, cut the boot
band.
. lfthe boot band is a locking tabs type, pry up the
tabs with a scr€wdriv€r and lift uo the snd of the
band.
2. Slide the outboard boot to the inboard ioint side.
TAB
OUTBOABD BOOT