Transmission HONDA CIVIC 2000 6.G Service Manual

trEM I merntc ENGLISH NorEs
SfAnff n i*nt-i- W"'gf,t MllSUBA r.u, l.z kw r'4 rg
CLUTCHClutch Type
Clutch Facing Area
M/T
CVTM/T
Single plate dry, diaphragm springTorque converterMulti plates wet sanP, hYdraulic160 cm,25 sq in
Synchronized 5-speed forward, 1 reverse
4 speed automatic, 1 reverse
Non stage speed forward, 1 reverse
Direct 1 : 1
TRANSMISSIONTransmission Type
Primary Reduction
M/TArrCW
Manualtransmission
Gear Ratio 1st2nd3rd4th5thReverse
Final Reduction Gear ratio
Gear tYPe
Engine type
D16Y5 | D16Y7 D16Y8 I 81642
3.2501.1821.1120.9090.7023.153
3.2501.1821.1120.9090.7023.153
3.2501.9091.2500.9090.1023.153
3.2302.1051.4581.1070.8753.000
*1:2 doorHatch back+2r 2-door Coupe,and 4 doorSedan
3.122 13.122"11.053" 1 4.250 | 4.266
Single helicalgear
Engine type
D16Y7 | D16Y8Automatic transmission
Gear Ratio 'lst
2nd3rd4thReverse
Final Reduction Gear ratio
Gear tYPe
2.6001.4680.9260.6381.954
2.122
0.9750.6381.954
1.3514.357
cwGear Ratio Low - O.D.Reverse
Secondary Reduction Gear Ratio
Final Reduction Gear Ratio
2.466 0.4492.4661.3334.357
AIRCONDITIONING
Cooling Capacity3,530 Kcal/h14,000 BTU/h
Compressor Type/MakeNo. of CYlindersCaPacitYMax. SpeedLubricant CaPacitY
Scroll/SANDEN
85.7 m//rev 5.22 cu inkev10,000 rpm130 mf 41l3tl oz.
| 4.6 imp ozsP,10
Compressor Type/ManufacturerNo. of CylinderCapacityMax. SpeedLubricant CaPacitY
Lubricant TYPe
Swash-plate/DENso10155.3 mf /rev 9.4 cu_in/rev76,000 rpm140 mf | 4 2l3fl oz,I 4 9lmp ozND'OIL8
Condenser TypeCorrugated fin
Evaporator TyPeCorrugated fin
Elower TyPeMotor InputSPeed ControlMax. CaPacity
Sirocco fan200w112v4 speed variable460 m3/h 16,200 cu ft/h
Temperature Control
Compressor Clutch TyPePower ConsumPtionDry, single plate, PolY-V'belt drive40 W max./12 V at 68'F (20'C)
Refrigerant TyPeouantity
HFC 134a (R'134a)
650 gos | 22.9 isoz
(cont'd )
4 . J-Z I

ILubrication Points
For the details of lubrication points and types of lubricants to be applied, refer to the lllustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul. Installation, etc.) contained in each section.
No.LUBRICATION POINTS
Engine
LUBRICANT
"Energy Conserving" grade oil,The oil container may also display the Apl Certification markshown below. Make sure it says ,,For Gasoline Engines.,,SAE Viscosity: See chart below,
I
TransmissionManualGenuine Honda MTF*1
Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF)*,
Genuine Honda CVT Fluid*3
Genuine Honda DOT3 Brake Fluid*a
Automatic
CVT
3Brake Line
ClL,tci t""e4
I
Genuine Honda DOT3 Brake Fluid*aPower steering gearboxSteering grease P/N 08733 - BO70EShift lever pivots (manual transmission)Grease with molybdenum disulfide7-:ti
9
10'l'l
l3
14
't7
18
19
20
2122
Release fork (manual trancmi Steering bootsTailgate hinges and latches (2-door HatchbacklSteering ball joints
Shift lever (automatic transmission)Pedal linkageBrake master cylinder pushrod
Super High Temp Urea crease (p/N 08798 - 9OO2)
i Multi-purpose grease
I
I
Honda White Lithium Grease
Multi-purpose grease
Silicone grease
@
Trunk hinges and latch (4-door Sedan and 2-doorCoupe)Door hinges upper and lowerDoor opening detentsHood hinge and hood latch-FUet T ter ttd
Clutch master cylinder pushrodThrottle cable end and throttle linkageRear brake shoe linkagesSteering wheel (back side)
23
E-
Caliper piston seal, dust seal,caliper pin. pistonThrottle cable end (dashboard lower panel)
Power steering system (for cars with p/S)
Air conditioning compressorComDressor oil:SANDEN: SPlo P/N 38897 - p13 -A01AH or 38899 - p13_ A01{For Refrigerant: HFC-134a (R-134a))
CERTIFICATION SEAL
ffi
NorE: The items m arked * 1, *2, +3, *4 and +5 on above chan are described as folows:*1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because itdoes not contain the proper additives.*2: Always use Genuine Honda premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affectshift quality.+3: Use Genuine Honda cVTfluid only usingotherfluid can affect tra nsmission operation and may reduce transmission life.*4: Always use Genuine Honda DoT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and dec.ease the lifeof the svstem.*5: Always use Genuine Honda Power steering Fluid. using any other type of power steering fluid or automatrc transmissionfluid can cause increased wear and poor steering in cold weather.
4-2
Recommended Engine Oil
Engine oil viscosity forambrent temperature ranges
API SERVICE LABEL

20. Remove the shift cable (CVT)
WASHER
Pt-Aslc
21. Disconnect the Power
switch connector, and
cramp.
LOCKNUT29 N.m {3.0 kgf m,22lbf'ft}
steering pressure (PSP)
remove the wire harness
CLIP
ll
I
Remove the radiator caP.
!!!@ usa care when l€moving the tadiator
Ap to avoid scalding by hot coolant or steam'
Raise the hoist to full height.
SHIFT CABLE
(cont'd)
25.
26.
27.
24. Remove the front tires/wheels and splash shield.
u x l.u mm SHIELD9.8Nm(1 0 kqt'm,
7.2lbf.ftl
Drain the engine coolant (see page 10-7). Loosen
the drain plug in the radiator.
Drain the transmission fluid Reinstall thedrainplug
using a new washer (see section 13, 14).
Drain the engine oil. Reinstall the drain bolt using a
new washer (see page 8-6).
28. Remove the shift rod and extension rod (M/T)
SHIFT ROD
EXTENSIONROD
8 x 1.25 mm22 N.m t2.2 kgf'm, 't6lbtft)
ER
6x1.0mm

39. Remove the left and right front mount and bracket'
MOUNT/BRACKET
40. Remove the rear mount bracket.
41. Remove the uPPsr bracket.
42. Remove the transmission mount bracket, then
remove the transmission mount.
44.
Check that the engine/transmission is completely
free of vacuum hoses, fuel and coolant hoses and
electricalwiring.
Slowly raise the engine approximately 150 mm (6 in)'
Check once again that all hoses and wires are discon-
nected from the engine^ransmission
Raise the engine all the way, and remove it from the
car.
UPPER
TRANSMISSION
45.
5-11

Engine Removal/lnstallation
Installation (cont'd)
Engino Inst!llation:
Install the engine in the reverse order of removal.Beinstall the mount bolts/nuts in the following sequence.Failure to follow these procedures may cause excessivenois€ and vibration, and reduce bushing life.
l, Install the transmission mount and bracket, thentighten the bolts on the frame side,
NOTE; Do not tighten the bolts/nuts on the trans_mission side.
CW;
10 x 1.25 mm38 N.m {3.9 kgt m. 28 lbt.ftl
5-14
I
I
2, Install the upper bracket, then tighten the nuts inthe numbered ssquence shown (O _ @).
l'
aO t2 x 1.25 mm74 N.m 17.5 kgf.m,O t2 x t.2s mm74 N.m 17.5 kgtm,rbrft)

3. Install the rear mount bracket, then tighten the bolts
in the numbered sequence shown (O - @).
CVT:
O 12 x 1.25 mm59 N.m (6.0 kgl'm,ilil lbf ftlReplace.
12 x 1.25 mm59 N.m 16.0 kgf'm,|:r tbf.tt)Replace.
O 12 x 1.25 mm59 N'm {6.0 kgf'm,/€ lbf.ftlReplace.
Except CVT:
,@ 14 x'1.5 mm
/ 8:t N.m {8.5 kgf.m,
/ 61 rbr.fr) Replace.
O 12 r 1.25 mm
59 N m 16.0 kgt m,(} tbf.fttReplace.
Olax1.5mm83 N.m 18.5 kgf.m,61 tbf.ftlReplace.
L
4. Tighten the bolvnuts on the transmission mount
bracket in the numbe.ed sequence shown (O - O).
@ t2 x t.2s mm7,1N.m (7.5 kg{ m, 54 lbf ftl
Tighten the bolts on the right front mounvbracket in
the numbered sequence shown (O - @).
GW:
O to x 1.25 mm54 N.m {5.5 kgl.m./|{} lbf.ftl
10 x 1.25 mm4,1 N.m {4.5 kgf.m. 33 lbf.ftl
(cont'd)
5-15
12 x 1,25 mmfl N.m 16.5 kgt.m,47 tbf.ftl

Engine Removal/lnstallation
Installation (cont'd)
Except CVT:
12 x 1.25 mm64 N.m (6.5 kgd.m,
Tighten the bolts/nut on the left front mount in thenumbered sequence shown {O - @).
(t 12 x 1.25 mm83 N'm (8.5 kgf.m,61 tbt.trl
/+4 N.m 14.5 kgf.m,33 lbt.trl
O 12 r 1.25 mm59 N.m 16.0 kgt.m,43 tbt.rtlSeplace.
5-16
\
7. Perform the following:
. Clean the areas where the driveshaft(s) and theintermediate shaft contact the transmission (dif_ferential) thoroughly with solvent or carburetorcteaner, and dry with compressed air.. Check that the set rings on the ends of the drive_shaft and intermediate shaft click into place.CAUTION: Use new set rings,. Adjust the shift cable (see section 14).. Adjust the throttle cable (see section 11).. Adjust the cruise control cable (see section 23).. Refill the engine with engine oil (see page 8-6).. Refill the transmission with fluid (see section 13,14).
. Refill the radiator with engine coolant (see page10-7).
. Bleed air from the cooling system with the heatervalve open (see page j0-7).
. Clean the battery posts and cable terminals withsandpaper, assemble them, then apply grease toprevent corrosaon.. Inspect for fuel leakage (see section j l).After assembling the fuel line, turn on l) the igni_tion switch (do not operate the starter) so that thefuel pump runs for approximately two secondsand the fuel line pressurizes. Repeat this opera_taon two or three times, then check for fuel leak_age at any point in the fuel line,

Flywheel and Drive Plate
Replacement
Manual Transmission:
816A2 engine:
Remove the eight flywheel bolts, then separate the fly-
wheel from the crankshaft flange. After installation'
tiohten the bolts in the sequence shown
RING GEAR HOLDER "-i
OTLAB PVOOlOO
D16Y5, D16Y7, D16Y8 engines:
Remove the six flywheel bolts, then separate the flywheel
from the crankshaft flange. After installation, tighten the
bolts in a crisscross Pattern.
RING GEABInspect ring gear
teeth lor wear or
damage.
RING GEARInspect ring gear
teeth lor wear orteetn lor wea( or /danase. ,///.'
12 x 1.0 mm103 N.m(10.5 kgf.m, 76 lbf.tt)
12 x 1.o mm1 18 N,m(12.0 kgI.m, 87 lbf.ftl
L
rurS;u'.\
$..3s'
Automatic Transmission:
Remove the six drive plate bolts, then separate the drive
olate from the crankshaft flange. Atter installation, tighten
the bolts in a crisscross Pattern.
t7.5 kgl.m, 54 lbl'ltl
12 x 1.0 mm74 N.m
7-7

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

PGM-FI System
Itil-"w Heated Oxygen Sensor (primary HO2S) (sensor 1l(Dl6Y5 engine with M/Tl
The scan tool indicates Diagnostic Trouble Code (DTC) p1162: A malfunction in the primary Heated OxygenSensor (Primary HO2S) (Sensor 1) circutt.
Doscription
The Primary Heated orygen sensor (Primary Ho2s) {sensor 1) operates over a wide airlfuel range. The primary Ho2S(Sensor 1) is installed in the exhaust manifold.
SEI{SORELEMENT
SENSORTERMINALS
ECM CONNECTOR C (31PIPRIMARY HO2S(SENSOR 1)8PCONNECTOR {Clir5)
female terminalsof femaleterminals
NOTE: lf DTC Pl162 is stored at the same time as DTC Pl167, troubteshoot DTC p1162 first, then recheck for DTC p1167.
(To page 11-147)
- lh6 MIL hes b6on reDorted on.- DTCPl162 ir 3tored.
Problom v6rificationi1. Do the ECM Reset Procedure.2. Start the engine.3. Wait at least tlvo minutes.
Test drive tor several miles withthe transmission in 3rd gear. Holdthe engine speed at 1,500 rpm.
ls DTC P1162 indicatod?
Intermittent tailuro, systom is OKat this timo. Check tor poor con-nections or loose wires at C145(Plimr.y HO2S, Senso. t) andECM,
ls DTC P1162 indicated?
Chock for an open in the wire(lP+ lins):1. Turn the ignition switch OFF.2. Disconnect ECM connector C{31P) from the ECM.3. Disconnect the 8P connectorfrom the Primary HO2S {Sen-sor 1).4. Check for continuity betweenthe Primary HO2S (Sensor 1)8P connector terminal No. 7and ECM connector terminalc23.
Repair open in the wire betwaonECM (C231 end Prim.ry HO2Slsen3or l).
Inspect lor poor terminal to termi-nal contact at the Primary HO2Slsensor 'l I connoctor and ECM.It terminal contect is OK, roplacelh6 Primrry HO2S {Sensor 1}.
11-146