trans HONDA CIVIC 2000 6.G Workshop Manual

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

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

Shift Indicator PanelATF Gooler/Hoses
Adjustment
1.Check that the index mark on the indicator aligns
with the E mark on the shift indicator panel when
the transmission is in NEUTRAL.
lf not aligned, remove the front console {see section
20).
Remove the shift indicator panel mounting
and adjust by moving the panel.
NOTE: Whenever the shift indicator panel is removed,
reinstallthe Danel as described above.
It,
14-357
lnstallation
1. Installthe ATF cooler, ATF cooler line assembly and
the ATF cooler hoses.
6x1.0mm11 N.m ('l 1 kgf.m,8.0lbl'ftlATF COOLER LINE ASSEMBLY
ATF COOLER HOSE
RADIATOR
6x1.0mm9.8 N.m 11.0 kgf'm, 7 8 lbf'ft)
ATF COOLER
Connect the ATF cooler
lines and ATF cooler. and
as shown.
hoses to the ATF cooler
secure them with the clips
1l lTf{il.T
6-8mm10.2 - 0.3 in)
33-35mm11.3 - 1.4 inl
2-1mm10.1 - 0.2 in)
2-ilmm{0.1 - 0.2 in)
ATF COOI..ER HOSES

Driveshafts
Inspection
Driveshaft Boot
Check the boots on the driveshaft for cracks, damage,
leaking grease and loose boot bands. lf any damage is
found, replace the boot and boot bands,
Loose Splines
Turn the driveshaft by hand and make sure the splines
and joint are not excessively loose. lf any damage is
found, replace the inboard joint.
Twisied or Cracked
Make sure the driveshaft is not twisted or cracked.
Reolace it if necessarv.
DRIVESHAFT
BOOT BANDS
1.
Removal
Loosen the wheel nuts slightly.
Raise the front of the vehicle, and support it with
safety stands in the proper locations (see section 'l).
Remove the wheel nuts and front wheels.
Drain the transmission fluid (see section 13 or 14).
Raise the locking tab on the spindle nut, then
remove the nut.
Remove the selJ-locking nut and flange bolts.
FLANGE BOLT10 x 1.25 mm
(cont'd)
16-3
1.

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
r 4).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
OOWEL BOLTS'10 x 1.25 mm
Remove the intermediate shaft from the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
'1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring.
2. Remove the intermediate shaft outer seal from theDeaflng suppon.
3. Remove the external circlip,