engine assembly HONDA CIVIC 2000 6.G Repair Manual

Symptom-to-Component Chart
Hydraulic System (cont'dl
G.
n,
set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
lf the clutch pack is seized or is excessively worn. inspect the other clutches for wear, and check the orificecontrol valves, CPC valve and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lmproper alignment or main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
lf the l st clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged. lf the 4th feed pipe is danFaged or out of round, replace the right side cover.
Replace the mainshaft if the bushing for the 1st feed pipe is loose or damaged. lf the 1st feed pipe is darn-aged or out of round, replace it.
A worn or damaged sprag clutch is mostly a result of shifting the transmission inthe wheels rotate in reverse, such as rocking the vehicle in snow.
or E position while
Inspect for damage and wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear u nder pin ion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1,2,3 and 4 if worn or damaged. lf transmission makes a clicking, grinding orwhirring noise,also replace mainshaft 4th gear, reverse idler gear. and countershaft 4th gear in addition to 1, 2, 3 or 4.lf differential pinion shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughlyclean transmission, flush torque converter, cooler and lines.lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and final drivengear.
Be very careful not to damage the torque converter housing when replacing the main ball bearing, you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the oroper roors.
Install the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
See flushing procedure, page 14-187 and 188.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the l-2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission hasno 1st gear.
lf the znd orifice control valve is stuck. inspect the 2nd and 3rd clutch oacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch oacks for wear.
lf the clutch pressure control valve is stuck closed, the transmission will not shift out of 1st gear.
lf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Inspect the frame for collision damage.
14-112

Pressure Testing
(cont'd)
Line Pressure/1st Clutch Pressurc Measurement
1. Set the parking brake, and btock both rear wheels securely.
2. Start the engine, and run it at 2,OOO rpm.
3. Shift to N or E position, then measure line pressure.
NoTE: Higher pressure may be indicated if measurements are made in shift lever positions other than @ or @ positron.
4. Shift to tq;l position, hold the engine at 2,000 rpm, and measure 1st crutch pressure.
1ST CLUTCH PRESSUREINSPECTION HOLE(Marked with "1")
LOCK.UP CONTROLSOLENOID VALVE A/8ASSEMBLY
VALVE A/B ASSEMBLY
PRESSURESHIFT LEVER
POS|TtONSYMPTOMPROBABLE CAUSEFLUID PRESSURE
StandardService Limit
LineN orENo (or low)
lrne pressureTorque converter,
ATF pump, pres-
sure regutator.
torque converter
check valve
830 - 880 kPa
{8.5 - 9.0 kgf/cm?,
120 - 130 psi)
780 kPa(8.0 kgf/cm', 110 psi)
1st ClutchD;lNo or low 1st
pressure
1st Clutch
\
14-120

Transmission
Removal
@Maks sure lifts, iacks and safety stands are placedproperly, and hoist bracket ate aftached to the cor_rec{ position on the engine lsee section 1).Apply parking brake and block rear whoels so vehiclewill not roll off stands and fall on you while workingunder it.
CAUTION: Use tender covers to avoid damaging paint-ed surfaces.
1, Disconnect the battery negative (_) terminal fromthe battery, then remove the positive (+) terminal.
2. Remove the intake air duct.
D16Y7 engins:
Remove the intake air duct and resonator.
D16Y8 engine:
Remove the intake air duct and the air cleaner hous-ing assembly,
3. Remove the starter cables and cable holder fromthe starter motor.
MOTOR CABLE
MOTOR CABLE
14-122
4. Remove the transmission ground cable, and discon_nect the lock-up control solenoid connector.
LOCK.UP CONTROLSOLENOID CONNECTOR
5, Disconnect the vehicle speed sensor (VSS) connec_tor and the countershaft speed sensor connector.
VEHICLE SPEED

Transmission Housing
Removal
MAINSHAFT
TRANSMISSION HOUSINGMOUNTING BOLTS18 Bolts
TRANSMISSIONHANGERTRANSMISSION HOUSING
MAINSHAFTSUB.ASSEMBLY
SENSOR WASHERlD16Y7 engine)
MAINSHAFTSPEED SENSOR
TRANSMISSIONHOUSING GASKETDIFFEBENTIALASSEMBLY
TOROUE CONVERTERHOUSING
SUB.ASSEMBLY
L,
14-134

Transmission
_\,]ffil
Reassembly (cont'd)
TRANSMISSIONHANGER
MAINSHAFTSUB.ASSEMBLY
*''
Ufln
$*U ./
TRANSMISSION HOUSINGMOUNTING BOLTS10 x 1.25 mm4{ N.m {4.5 kg{.m,33 lbI.ft)
TRANSMISSION HOUSING
REVERSE GEARCOLLAR
REVERSE GEAR
LOCK WASHER
SHIFT FORK
MAINSHAFT SPEEDSENSOR WASHER(D16Y7 engine)
MAINSHAFT
COUNTERSHAFTSUB.ASSEMBLY
OIFFER€NTIALASSEMBLY
SPEED
TRANSMISSIONHOUSING GASKET
TOROUE CONVERTERHOUSING
14-178

Transmission
1.
lnstallation
Flush the ATF cooler as described on page l4-187
and 14-188.
Install the torque converter assembly securely with
a new O-ring on the mainshaft
STARTER MOTOR
14 mm DOWEL PIN
TOROUE O-RING
CONVERTER Replace
lnstall the starter motor on
housing, then install the two
the torque converter housing.
lil mm DOWEL PIN
the torque converter
14 mm dowsl pins in
MOUNTINGBRACKET
Place the transmission on a jack, and raise it to the
engine assembly level.
Attach the transmission to the engine, then install
two transmission housing mounting bolts and two
rear engine mounting bolts.REAR ENGINEMOUNNNG BOLTS1,1r15mm&| N.m 18.5 kgf m, 61 lbf'ft]
Replace.
64 N.m {6.547 tbf frlWASHER
ENGINE
TRANSMISSION HOUSINGMOUNTING BOLTS12 x 1.25 mm
45 N.m {4.5 kgf.m,
JACK
6. Install the transmission mount bracket.
12 x 1.25 mm6il N.m {6.5 kgf.m, a7 lbf'ft)
12 x 1.25 mm74 N.m (7.5 kgf.m,54 tbt.fr)
TRANSMISSION MOUNT
7.Install the remaining transmission housing mount-
ing bolts and remaining rear engine mounting bolt.
REAR ENGINEMOUNTING BOLT14 x 1.5 mmel N.m (8.5 kgt'm,61 tbl.ft)Replace.
HOUSING
MOUNTING BOLTS12 x 1.25 mmg N m (6.5 kgf m, 'l? lblftl
8. Remove the transmission jack.
(cont'd)
14-183

Transmission
Installation {cont'd)
Connect the lock-up control solenoid connector. andinstall the transmission ground cable.
6 x '1.0 mm12 N.m {1.2 kgf.m, 8.7 lbl.ft}
LOCK.UP CONTROLSOLENOID CONNECTOR
Connect the staner cables on the staner motor. andinstall the cable holder.
NOTE; When installing the starter cable terminal.make sure that the crimped side of the ring terminalis facing out (see section 23).
6x1.0mm12 N.m 11.2 kg{.m.8.7 tbtftl
{0.9 kg'f.m, 7 lbf.ftl
TRANSMISSIONGROUND CABLE
b
14-186
STARTER CAELE
24. Installthe intake air duct.
D16Y7 engine:
Install the intake air duct and the resonaror.
D16Y8 engine:
lnstall the intake air duct and the air cleaner hous_ang assembly.
25. Refill the transmission with ATF (see page 14_1.18).
26. Connect the positive (+) cable first. then the nega-tive (-) cable to the battery.
27. Check the ignition timing (see section 23).
28. Start the engine. Set the parking brake, and shift thetransmission through all gears. three times. Checkthe shift cable adjustment (see page 14_190).
29, Check the front wheel alignment (see section 1g).
30. Let the engine reach operating temperature (thecooling fan comes on) with the transmission in Nor @ position, then turn it off and check the fluidlevel (see page 14- 7).
31. Road test as described on pages 14-113 thru ,14_116.

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
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When
hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse
brake piston move. This presses the friction djscs and the steel plates together, locking them so they don't slip. Power is
then transmitted through the engaged clutch pack to its hub-mounted gear. and through engaged ring gear to pinion
gears.
Likewise, when the hydraulic pressure is bled from the clutch pack and the reverse brake piston cavity, the piston releases
the friction discs and the steel plates, and they are free to slide past each. This allows the gear to spin independently on its
shaft, transmitting no power.
Start Clutch
The start clutch, which is located at the end of the driven pulley shaft, engages/disengages the secondary drive gear.
The start clutch is supplied hydraulic pressure by its ATF feed pipes within the driven pulley shaft.
Forward Clutch
The forward clutch, which is located at the end of the drive pulley shaft, engages/disengages the sun gear.
The forward clutch is supplied hydraulic pressure by its ATF feed pipe within the drive pulley shaft.
Reverse Brake
The reverse brake, which is located inside the inte.mediate housing around the ring gear, locks the ring gear in E posi-
tion. The reverse brake discs are mounted to the ring gear and the reverse brake plates are mounted to the intermediate
housing. The reverse brake is supplied hydraulic pressure by a circuit connected to the internal hydraulic circuit.
Planetary Gear
The planetary gear consists of a sun gear, a carrier assembly, and a ring gear. The sun gear is connected to the input shaft
with splines. The pinion gears are mounted to the carrier which is mounted to the fo.ward clutch drum. The sun gear
inputs the engine power via the input shaft to the planetary gear, and the carrier outputs the engine power. The ring gear
is only used for switching the rotation direction of the pullev shafts,
In E. E, and E positions (forward range), the pinion gears don't rotate and revolve with the sun gear, so the carrier
rotates. In E] positjon {reverse range), the reverse brake locks the ring gear and the sun gear drives the pinion gears to
rotate. The pinion gears rotate and revolve in the opposite direction from the rotation direction of the sun gear, and the
carrier rotates with pinion gear revolution.
Pulleys
Each pulley consists of a movable face and a fixed face, and the effective pulley .atio changes with engine speed. The
drive pulley and the driven pulley are linked by the steel belt.
To achieve a low pulley ratio, high hydraulic pressure works on the movable face of the driven pulley and reduces the
effective diameter of the drive pulley. and a lower hydraulic pressure works on the movable face of the drive pulley to
eliminate the steel belt slippage. To achieve a high pulley ratio, high hydraulic pressure works on the movable face of the
drive pulley and reduces the eifective diameter of the driven pulley, and a lower hydraulic pressure works on the movable
face of the driven pulley to eliminate the steel belt slippage.
b
14-198

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