1997 HONDA CIVIC d16

Cou ntershaft
1. Remove the needle bearing using the special tool as
shown. then remove the oil guide plate
3/g " -16 SLIDE HAMMER
{Commercially available)
PULLER, 25-40 mm07736-AO1000A
\
2. Install the oil guide Plate, then
bearing into the clutch housing
tools as shown.
d rive the needle
using the special
'1: ATTACHMENT, 42 x 47 mm
07746-0010300*2: ATTACHMENT, 52 x 55 mm
07746 -0010400
ORIVER07749 -0010000
CLUTCHHOUSING
NEEOLE BEAFING
GUIDE PLATE
NEEOLE BEARING
*1: D16Y7 enqine*2: D16Y5, D16Y8 engines
OIL GUIDE PTATE
13-35

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

I
PCM CONNECTOR B {25P1 {cont'dl
Terminal NumberSignalDescriptionMeasuring Conditions/Terminal Vohage
811SHBShift control solenoid valve B
control
In 1st gear and 2nd gear in -q1, q11 position,
and in E] position: Battery voltage
In 3rd gear and 4th gear in lD.J, [Dr- position: 0 V
B't2SLUInterlock controlWhen ignition switch is ON (ll), brake pedal
deoressed and accelerator Dedal released: 0 V
813D4 INDD4 Indicator light controlWhen ignition switch is first turned ON (ll):
Battery voltage for two seconds
In E position: Baftery voltage
B't 4NMSGMainshaft speed sensor groundAlways: 0 V
E tcNMMainshaft speed sensor signal
input
Depending on engine speed: Pulsing signal
When engine is stopped: 0 V
816ATP RAy'T gear position switch Eposition signal input
InE position: 0V
In other than E position: Battery voltage
817ATP 2A/T gear position switch E posi-
tion signal input
InE position: 0V
In orher than E position: Battery voltage
818 to 821Not used
s22NCSGCountershatt speed sensor groundAlwaysr 0 V
B23NCCountershaft speed sensor signal
input
Depending on vehicle speed: Pulsing signal
When vehicle is stopped: 0 V
B24ATP D4Ay'T gear position switch lor posi-
tion signal input
InEposition:0V
In other than 6 position: 5 V
ATP NPA,/T gear position switch E and
N position signals input
InE and E positions: 0V
In otherthan E and N] positions: Battery voltage
PCM CONNECTOR C {31P)
Terminal NumberSignalDescriptionMeasuring Conditions/Terminal Voltage
Cl to C6- see section 11 -
c1Service check signalWith ignition switch ON (ll) and service check
connector oDen; 5 V
With ignition switch ON (ll) and service check
connector connected with sDecial tool: 0 V
C8 to Cg- see section 11 -
c10VBUBack-up power systemAlways battery voltage
C11 to C31- see section '11 -
PCM CONNECTOR D (16P}
Terminal NumberSignalDescriptionMeasuring Conditions/Terminal Voltage
Dl to D4- see section 11 -
D5STOP SWBrake switch signal inputBrake pedal depressed: Battery voltage
Brake pedal released: 0 V
D6 to D16- see section 1 l -
14-43

FCM CONNECTOR D {16P)
\o
14-47
Terminal NumberSignalDo3criptionMeasuring Conditions/Torminal Vohage
D1LCALock-up control solenoid valve A
control
When lock-up is ON: Battery voltage
With no lock-up: 0 V
SHBShift control solenoid valve B
control
In E position, in 1st and 2nd gear in E, E
position: Battery voltage
ln 3rd gear in E, E, in 4th gear in E posi-
tion;0 V
D3LCBLock-up control solenoid valve B
control
When full lock-up: Battery voltage
With half lock-up: Pulsing signal
D4Not used
D5VB SOLLock-up control solenoids, shift
control solenoids and linear
solenoid power supply electrode
with ignition switch oN (ll): Battery voltage
With ignition switch OFF: 0 V
D6ATP RAy'T gear position switch
E position input
tnEposition:0V
In other than E position: Approx. 10 V
SHAShift control solenoid valve A
control
In E] position, in 2nd and 3rd gear in p!, [Q]
position: Battery voltage
In 1st gear in E, @ position, in 4th gear in El
Dosition: 0 V
D8ATP D3A/T gear position switch
E position input
In E position:0V
In otherthan @ position: Approx. 10 V
D9ATP D4Ay'T gear position switch
E position switch
In El position: 0 V
In other than E position: Approx. 5 V
D10NCCountershaft speed sensor signal
input
Depending on vehicle speed: Pulsing signal
When vehicle is stooped: 0 V
D11NMMainshaft speed sensor signal
Inpur
Depending on engine speed: Pulsing signal
When engine is stopped: 0 V
D't2NMSGMainshaft speed sensor ground
D13ATP NPAy'T gear position switch E and
E position input
InE and E positions: 0V
In other than E and E positions: Approx. 10 V
D14AfP 2Ay'T gear position switch
E position input
tnEposition;0V
In other than E position: Approx. 10 V
D16NCSGCountershaft speed sensor
ground

Troubleshooting Flowchart - Countershaft Speed Sensor
NOTE: Record all freeze data before you troubleshoot
Po$iblo Cause
. Loos€ or fsulty conneclionbetween the PCM and vehicle
hainoss' Disconnectod countersh.ft
spoed senaof connoctor. Short or opgn in counteBhaft
3Deed aensor wire. Faulty counloEhaft 3p€ed sen'
soa
COUNTERSHAFf SPEED
SENSOR CONNESTOR
Terminal side oI male terminals
FCM CONNECTOR D I16PI
rconl c
1+93
NC IBLUI
. OBD ll Scan Tool indicat6 Code
PO720.. Self-diagnosis E indicator light
blinks nin6times.
Check the countershaft sPeed
sensor installation, and check it
lor damage.
ls the countershaft speed sensor
installed properly, and not dam-
aged?
Reinstall or replace and rechock.
Measurg Counlershatt SPeed
Sgn3ol R6istance at tho Son3ol
Connector:1. Disconnect the 2P connector
from the countershaft sPeed
sensor.2, Measuro countershaft sPeed
sensor resistanca at the sensor
connector.
ls the resistance 400 - 600 O?
Chcck CounteEh.tt SPeed Sen'
sor lor a Short Circuit:1. Disconnect the D {16P) con
nector trom the PCM.2. Check lor continuity between
body ground and the D10 ter_
minal and D16 terminal indi-
vid!ally.
R6oai. short in tl|€ wi.6a bstwa€n
the D10 and D16 t.rminali end
tho countdthatt rP€od senaor.
To page 14 94
Wire side of temale terminals

Electrical Troubleshooting ('gg - 00 Modelsl
From page 14-93
Measure CounteJahaft SpeedSensor Circuit tor an Open:1. Connect the countershaltspeed sensor connector,2. Measure the resistancebetween the Dl0 and D16 termtnats.
Roptir loo.€ t6.minal or opan inth6 wir€! betwo€n lho D10 lndD16 t.rmina13 and the count.r-shatt apaad aaNor.
ls the resistance 400 - 600 O?
Check for loose t.rminal frt in thePCM connectors. It necalsary,3ubstitute a known-good PCMand recheck.
Troubleshooting Flowchart - Countershaft Speed Sensor (cont,d)
PCM CONNECTOR D I16PI
Wire side of female terminals
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14-94

Mai nshaft/Cou ntershaft
Linear Solenoid AssemblySpeed Sensors
Replacement
1. Remove the mounting bolts and the linear solenoid
assemory.
Clean the mounting surfaceand flu id passages.
6x1.0mm12 N.m 11.2 kgl m,8.7 tbf.ftl
@
@
GASKET
Clean the mounting surface and fluid passage of the
linear solenoid assembly and transmission housing.
Install a new linear solenoid assembly with a new
gasl(et.
NOTE; Do not pinch the gasket when installing the
linear solenoid; make sure that the gasket is installedproperly in the mounting groove of the linear sole-
noid.
Check the linear solenoid connector for rust, dirt or
oil, and connect it securely,
LINEARSOLENOIDASSEMELY
I
14-108
Replacement
't.
6x128.7
Remove the 6 mm bolt and the countershaft speed
sensor from the right side cover.
COUNTERSI{AFTSPEED SENSOR
O.RINGReplace.
MAINSHAFTSPEEDSENSOR
MAINSHAFT SPEEDSENSOB WAS}IER(D16Y7 enginel
6x1.0mm12 N.m (1.2 kgf m,8.7 tbf.ft)
1.0 mmN.m (1.2 kgf.m,rbf ft)
\\
/,
%/E:)
Remove the 6 mm bolt and the mainshaft sDeed
sensor from the transmission housino.
Replace the O-ring with a new one before installing
the countershaft speed sensor or th€ mainshaft speed
sensor.
NOTE: Installthe mainshaft speed sensor washer on
the mainshaft speed sensor. The mainshaft speed
sensor washer is used on models with the D'|6Y7
engine.

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