Trouble shooting HONDA CIVIC 2000 6.G Service Manual

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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
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Troubleshooting
Reverse Gear Noise Reduction System
Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.
The resulting speed difference between mainshaft and reverse idler gear produces gear noise.
The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting
into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate. This causes the sth synchro set
to stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less
gear norse.
NOTE: This system is not a fully-synchronized gear noise reduction system.
Therefore, you may hear gear noise when
O you shift into reverse with the vehicle not yet completely stopped.
@ you shift quickly into reverse during fast idling.
-
Gear noise is oresent when shift-ing into reverce after the engineis started.
Test-drive the vehicle.
ls the gear noise present whenshifting into 5th gear?Beplace the 5th synchro hub and3leeve e3 a set,
Measure the clearance between5th shift fork and 5th synchrosleeve {see page 13'26).
ls the clearance 1.0 mm (0.04
in) or less?
Measure the MBS shift piece pin(see page 13-27).
ls ( 6.8 mm (0.27 in) or more?Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4

Automatic Transmission
Special Tools ......... .....'."".'-.-.' 14'2
Description .,....................-...... 14-3
power Flow ......,................. 14"6
Elestronic Control System .... . ................'..'.'.. 14-13
Hvdraulic Control .....'......" 1'l-19
Hydraulic F|ow...... .'.'.".'....11-21
Lock-up System '............ ... t/t'33
Electrical System
Component Locations....,.............'......'.............'.,. 14'39
PCM Circuit Diagram
lA/T Control Syst€m: '96 - 98 Models) .........'.. 1/t-40
PCM Tarminal Volt8ge/Measuring Condhions
{'96 - 98 ModeblA/T Control System ............
PCM Circuit Disgram(A/T Conlrol System: '99 - 00 Modsls) '..........' 14-44
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)A/T Control System ...
Troubleshooting Proceduros ....
Symptom-to-ComPonent Chari
Efectricaf SFiem - '96 - 98 Models '..-.-..."'.'..11-52
Eloqtrical System -'99 - 00 Modols ... .........". 1+54
EleclricatTroubl$hooting ('96 - 98 Models)
Valve Body
Repair .................... ........'.... 14-139
Valve
Assembly
ATF Pump
1,1-1i10
Inspection ...........'.......... 14-141
Main Valvs Body
Disass€mbf y/lnspoction/R.sssembly .'.'.'.'.. -. -. 1 1-1 12
Secondsry Valve BodY
Disa$embfy/lnspoction/Rsassembly ......'.'.'.'. 11-111
Regulator Valve Body
Disa$embly/lnspoction/Rea3sembly ..........'... 14-1{5
Servo Body
Disassombly/lnsp€ction/Reassembly .".'........ 14-146
Lock-up Valv6 Body
Dis$s.mbf y/ln3poction/Rea$embly .'.. -. -..'.'.' 1 1-1 17
Mainsh!ft
Dkassembly/lnep€ction Reassembly ..'...'........ 14'148
Inspoction .............'..........'. l it-149
Countsrshaft
Disa$embly/lnspeqtion/Rea3sembly .......'...'.. 1a-l51
Dba$ombly/Re$s.mblY11-152
til-46
I rl-48
Troubleshooting Flowcharts
Electrical Troubleshooting ('9!t - 00 Models)
Troublsshooting Flowchart3
Lock-up Control Solenoid vslvo A/B AssemblY
RePlacoment
Shift Cont.ol Solenoid Valve A/B A3sembly
Inspestion
Ona-way Clutch
Disassembh/lrupoction/Rca$embly .. "'........ l4-155
Clutch
lllustlttcd Ind.x {A48A, B4RA Transmlssion) ..' 14-156
tustr.tod Index (MrnA Transmi$ionl ............ til-158
...................... 14-153
L
14-56
1+81'
14-105
1+105
Replacoment ......
Mainshaft/Countorshaft Spo€d Sonsors
Replacemsnt ......'."'........... lit'108
Hydraulic System
Symptom-to-Componeni Chart
Hydraulic Sydemr+109
t4-113
1+116
11-117
Rea$emblY
14-106 Difforrr ial
llhdraied Index........ t4-156
B.ckhrh ln3poction. 14-167
Boaring Roplacemont..-..........11-167
..... 14-108 Diftrrsniial Carrior Repl8cemeni .'.-.............'...' lil-168
Oil Sall Romovalt4-t 59
Oil Soal ln3tallstion/Sidc Clearance'......'.....'... 1'l'169
Torqua Convertcr Housing Boarings
Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
Counio6hatt Betring R.plscem.nt ..'...... ....... 14-173
Test.....,......14-106
14-107
14-160
11-162
11-171
11-175
Replacement
Test .....,.,..........
Road Te3t
Linear Solenoid AsssmblY
Stall Speed
lllustrated Indax
Transmission/End Cover'. ....
Transmission Hou3ing,.............'.'......'....""..-.-.. 11-128
Torque Conve.ter Housing/Valvo Body ........... 14-130
End Cover
14-itB Park Stop
1+119 In3pection/Adiustmsnt...'......'.'............'...."""'14-175
Transmbgion
Reassombly
11-122 Torquo Convertet/Drivr Plsie ............'.'............'.. . l4-182
Transmission
11.726 Inrtallation
Tranlmission Housing Boarings
Msinsh.ft /CounteEhaft Bearings
B!pltcomgnt
Rcvo.3s ldlor Gear
lnrtallation
Cooler Flushing ..
Shift Cabls
Test
Fluid Level
Checkin9 .........."..'.'.....
Changing
Pressure Testing
Transmission
Transmission
Rgmoval ..
lil-176
.'..........'.'.'..... 1'l-183
.... lil-187
11-132Adiustmont
RemovaUlnttallation1,1-190
lit-191Transmisgion Housing
Removal ... '.'...... ......'..... 14-l3il
Tolque Convgrter Housing/valvs Body
Rsmoval .........,...... ............. 14-136
Valve CaDs
Description .......'................. t 4'138
Shift lndicator Panel
Adiu3tmant ..'.................. 14-192
ATF Coolor Hoses
Connection ..,............,.,....... l'l-192
Shift Lever .,........

Troubleshooting Procedures
1.
2.
(cont'dl
Remove the kick panel on the passenger's side {see section 20}.
Remove the PCM. and turn the PCM over.
Inspect the circuit on the PCM according to the troubleshooting flowchart with the spocial tools and a digital multime-ter as shown.
How lo Use tha Backprobe Set
Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. Using the wireinsulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from thewire side until it comes in contact with the terminal end ofthe wire.
BACKPROSE
BACKPROBE SET07saz - (xtl(xtoA
{two required)
DIGITAL MULNMEIER(Comm€rcially 6vailabl€l-aHM-32-003
t..
14-50
or equival€nt

PCM Reset Procedure
1. Turn the ignition switch off.
2. Remove the BACK UP fuse (7.5 A) from the under-hood fuse/relay box for '10 seconds to reset the PCM'
NOTE:
. Disconnecting the BACK UP fuse also cancels the radio preset stations and clock setting Make note of the radio
presets before removing the luse so you can reset them
. in" gCfU memory can also be cleared by using the OBD ll Scan Tool or Honda PGM Tester'
Final Procedure
NOTE: This procedure must be done after any troubleshooting.
1. Turn the ignition switch OFF.
2. Reset the PcM.
3. Disconnect the oBD ll scan Tool or Honda PGM Tester from the Data Link connector, or remove the special tool from
the Service Check Connector.
4. Turn the ignition switch ON (ll), and set the radio presets and clock setting'
5'ToVerifytheprob|emisrepaired,test.drivetheVehic|eforseveralminutesatspeedsover30mph(48km/h).
14-51

Electrical Troubleshooting (,96 - gg Models)
Troubleshooting Flowchart - Lock-up contror sorenoid Varve A
Po$ible Cau3e
. Disconnecled lock-up controlsolenoid valvo A connector. Short or open in lock-uD controlsolenoid valv€ A wire. Fauliy lock-up contlol solonoidvalve A
PCM CONNECTORS
Wire side of female terminals
. OBD ll Scrn Toot indicates CodeP1753.. Self-diagnosis @ indicatorlight blinks once.
Check for a Short to Powo.:1. Turn the ignition switch OFF.2. Disconnect the A (32p) and B(25P) connsgl6ps 1rq- thaPCM.3. Turn the ignition swjtch ON 0t).4, Measure the voltage betweenthe 85 and Ag or A22 terminals.
Repair shoit to power in the wirebetw€en the 85 terminal and thglock-up coDtrol tolenoid valve A.
Mea3ure Lock-up Control Sole-noid Valve A RGislance:'1. Turn the ignition switch OFF.2. Measure the resistancebetween the 85 and A9 or A22terminals.
Check lor looso PCM conn€ctoB.lf nece$.ry, substituto a known-good aolonoid valve ass€.nblv olPCM end rech6ck.
ls the resistance 12 - 25 O?
NOTE: Record allfreeze data before you troubleshoot.
A l32P)
To page'14-57

Electrical Troubleshooting ('96 - 9g Modelsl
Troubleshooting Ftowchart - Lock-up control sorenoid Varve B
Possible Cause
. Disconnected lock-up controlsolenoid valve B connector' Short or open in lock-up controlsolonoid valve B whe. Faulty lock-up control solenoidvalve B
PCM CONNECTORS
Wire side of female terminals
. OBD ll Scan Tool indicrtes CodeP1758.. Self-diagnosis E indicrtor lightblinkstwice.
Check for a Shon to Power:1. Turn the ignition switch OFF.2. Disconnect the A (32p) and B(25P) connectors from thePCM,3. Turn the ignition switch ON t).4. Measure the voltage betweenthe 84 and A9 or A22 termi-nals.
Repeir short to power in the wirebetween the 84 teiminal and thelock-up control solenoid valve B.
Moasure Lock-up Control Sole-noid Valve B Resistance:1. Turn the ignition switch OFF.2. Measure the resistancebetween the 84 and Ag orA22 terminals.
Check for loose FCM connectors,lf necessary, substitute a known-good solenoid valve assembly olP1CM and rech6ck.
ls the resistance 12 - 25 O?
NOTE: Record all freeze data before you troubleshoot.
A {32P)
To page 14-59
t-

Electrical Troubleshooting ('96 - 9g Models)
Troubleshooting Flowchart - A/T Gear position Switch (Shortl
NOTE: Record allfreeze data before you troubleshoot.
Poiriblo Caus6
. Short in A/T go.. positionawhch wira. Fauhy A/T goa. position swhch
NOTE: Code P1705 (5)the PCM receives twoinputs at the same time.
is caused whengear position
' OBD ll Scln Toot indic.tes Cod6P1705.. Sofidi.gno3b E indicato] tighrblinksfivatim...
Observo th. A/T Go.r po3ition
Indicator:1. Turn the ignition switch ON l).2. Observe the A"/T gear positionindicator, and shitt to eachposttron,
Do any indicatoG stay onwhen the shift lever is not inthose positions?
Tho sy3tem b OK.t this timo.Check th6 wilc harnari for dam-rga.
M.r.ur. ATP R Vohlge:1. Shift to all positions otherthanE.2. Nileasure the voltage betweenthe 816 and Ag or A22 tormi-nats,
Check for short in tha wirobstwacn the 816 tcrminal and th6A/T go.r porition rwitch or A/Tg..r position indicltor. It wira i3OK, ch.ck for loo!€ FCfit connoc-to13. lf nacetaary, subrtitute aknown€ood Pcllt and roa|rsck.
ls there battery voltage?
Meesur. ATP NP Vohage:1. Shift to allpositions oth€r thanEorE.2. Moasure the voltage betweenthe 825 and A9 or A22 terminats.Check for short in the wireb.tw..n th6 B:I5 torminrt and th.A/T gclr poahion indicator. o. .short in tha wirrs between th.A/T gclr position indicator rndthe A/T gerr poiition switch. lfwir.3 r.o OK, chack tor loosoPCM conn.ctorr. It n.cosarry.sub.tituto a known-good pCM.nd r.chock.M.Gur. ATP D4 Voltago:1. Shift to allpositions otherthanlD.l.2. Measure the voltage betw€enrhe 824 and Ag or A22 termi-nals.
Check tor 3hort in tho wirobc{wocn the 824 terminrl and thoA/T ge.r poiition switch. lI wileia OK, chock tor loo3o plCM con-ncctoaa. It nacossarv, sublthute aknown-good PCM and rech€ck.
ls there approx. 5 V?
PCM CONNECTORS
Wire side of female terminals
YES
To page 14-6':
14-60

Electrical Troubleshooting ('96 - gg Modelsl
Troubleshooting Flowchart - A/T Gear position Switch (Open)
. OBD ll Scan Tool indicates CodeP1706.. Self-di.gnosk E indicator tightblinks six timos.
Measure ATP 04 Voltege:1. Shiftto E position.2. Measure the voltage betweenthe 824 and A9 or A22 terminals,
ls there voltage?
Possible Causo
. Disconnected A/T gear positionswitch conn€ctor. Open in A/T gear positionswitch wire. Faulty A/T gear position switch
Wire side of female terminals
NOTE: Record all freeze data before you troubleshoot.
Moasure ATP I Voltage:1. Turn the ignition switch ON 1 ).2. Shift to E position.3. Measure the voltage betweenthe B'f6 and Ag ot A22 tetmi-nats.
Ropai. op€n in the wire betwe€nthe Bl6 terminal.nd the A/T gearposition swhch.
Measur€ ATP NP Voltage:1. Shift to E or E position.2. Measure the voltage betweenthe 825 and A9 or A22 termi,nals,
Repeir open in the wir€ betweentho B25 terminal and th6 A/T geerposition indicator or tho A/T 96.rposition 3witch.
Rcpair open in the wire betweentto 82{ to.minal and th6 A/T geatlrosition 3witch.
To page 14 63
PCM CONNECTORS
NO
1
L
+62

Electrical Troubleshooting ('96 - 98 Modelsl
Troubleshooting Flowchart - Shift Gontrol Solenoid Valve A
Po$ible Cau3e
. Disconnected shift controlsolenoid valve A connector. Short oi open in shift controlsolenoid valve A wire. Faulty shirt control solenoid
PCM CONNECTORS
' OBD ll Scan Tool indicates CodeP0753.. Sett{iagnosis E indicator lightblinks seven tim6.
Check tor a Short to Power:1. Turn the ignition switch OFF.2. Disconnect the A (32P) and B{25 Pi connectors trom thePCM.3. Turn the ignition switch ON {ll).4. Measure the voltage betweenthe 83 and A9 orA22 terminals.
Repair short to powe. in the wir6between the 83 terminal .nd theshift control solonoid valvo A.
Moa3ure Shift Control SolenoidValve A Resistanc€:1. Turn the ignition switch OFF.2, Measure the resistancebetween the 83 and A9 or A22terminals.
Ch€ck for loose PCM connectors.lf n€c6srry, subatitute a known-good solenoid valve a3,sembly orPCM end rocheck.
ls the resistance 12 - 25 0?
NOTE: Record all freeze data before you troubleshoot.
A t32Pl
To page 14-65
Wire side ol female terminals