1999 HONDA CIVIC Crankshaft pulley bolt

Timing Belt
lnstallation (cont'dl
3. Install the timing belt tightly in the sequence shown.
@ Timing belt drive pulley (crankshaft) + @Adjusting pulley * @ Water pump pu ey + @ Intakecamshaft pulley + @ Exhaust camshaft pulley,
NOTE: Make sure the timing belt drive pulley andcamshaft pullevs are at TDC,
Loosen and retighten the adjusting bolt to tensionthe timing belt.
Install the lower cover and middle cover.
NOTE: Clean the middle and lower covers beforeinstalling.
Install the crankshaft pulley, then tighten the pulleybolt (see page 459).
Rotate the crankshaft pulley about five or six turnscounterclockwise so that the timing belt positions onthe pulleys.
Adjust the timing belt tension (see page A611.
7.
6-64
a
9. Check that the crankshaft pulley and camshaft pul-leys are both at TDC.
CRANKSHAFT PULLEY
CAMSHAFT PULLEY:
lf the camshaft and crankshaft pulleys are not posi-tioned at TDC, remove the timing belt, adjust theposition following the procedure on page &63, thenreinstall the timing belt.
After installation, adjust the tension of each belt.
. See section 23 for alternator belt tension adjust-ment.
. See section 22lor NC compressor belt tensionadiustment,
. See section 17 for P/S pump belt tension adjust-ment.
'l
10.
11.
I
"UP" MARKS

Removal
Engine removal is not required for this procedure.
!@@ Make sure jacks and safety stands are placed
properly and hoist brackels are attached to correst posi-
tion on the engine,
CAUTION:
o Use fender covers to avoid damaging painted sur-
faces.
To avoid damage, unplug the wiling connectors
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F {38'Cl
before loosening the retaining bolt.
NOTE:
. Unspecified items are common.
. Mark all wiring and hoses to avoid misconnection.
AIso, be sure that they do not contact other wiring or
hoses or interfere with other parts.
o Inspect the timing belt before removing the cylinder
n eao.
. Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (see page 6-64).
1. Disconnect the negative terminal from the battery.
Drain the engine coolant {see page 10-7).
. Remove the radiator cap to speed draining.
Remove the strut brace (see page 5-2).
Remove the intake air duct and air cleaner housing
(see page 5-3).
Remove the adjusting bolt and mounting bolt, then
remove the power steering (P/S) pump belt and pump
(see page 5 5).
2.
3.
4.
\
ADJUSTING
6. Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (A/C) com-
pressor belt.
IDLER PULLEY BRACKETBOLT10 x 1.25 mm44 N.m {4.5 kg,l.m, 33 lbt.ft}
7. Loosen the mounting nut and lock bolt, then remove
the alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgf.m,17 tbtftl
ALTERNATORBELT10 x 1.25 mm,l,l N.m {4.5 kgf.m,33 tbf.ft,
(cont'd)
6-67

19. Remove the engine stiffener and the torque con-
verter cover.
Remove the eight drive plate bolts one at a tlme
while rotating the crankshaft pulley.
Remove the distributor.
Attach a hoisting bracket to the engine, then lift the
engine slightly.
HOISTBRACKET
20.
21.
COVER
23. Place a jack under the transmission. and ra6a :'.
transmission iust enough to take weight otf ol tF.
mounts. then remove the transmission mounl
TRANSMISSIONMOUNT BRACKET
Remove the transmission housing mounting bolts
and the rear engine mounting bolts.
Pull the transmission away from the engine until it
clears the 14 mm dowel pins, then lower it on the
transmission jack.
TRANSMISSION HOUSING
lf necessary, remove the torque converter anc:"
starter motor.
24.
25.
1+16

Transmission
Installation (cont'dl
9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque. then to thefinal torque, in a crisscross pattern.
After tightening the last bolt, check that the crank-shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6x1.0mm12 N.m (1.2 kgt m,8.7 rbt ft)
I 1.25 mm2/t N.m {2.4 kg{.m,17 tbt ftlCONVERTEB
10. Install the torque convener cover and the €nginestiffener.'11. Tighten the crsnkshaft pull€y bolt, if necessary (see
section 61.
12. Connect the ATF cooler hoses to the ATF cooler lines(see page 1,t192).
ATF COOIIRUNE
10 x 1.25 mma,l N.m {4.5 kgl.m,33 rbt.fttRIGHT FRONT 12 x 1.25 mmMOUNT/BRACKET 6.t N.m (6.5 kg{.m,47 tbt ftl
13. Install the right front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Install the control lever with a new lock washer tothe control shaft, then install the shift cable cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHERReplace.
8 x 1,25 r'|m22N-m12.2 tgt m. 16lbnftl
x 1.0 mmtit N.m 11.4 kgt m,10 tbr,ft,
15. lnstall the exhaust pipe A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_ilar.
Replace.
GASKETReplace.
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 lgf.m,40 tbt ftl
NUTSELF.LOCKING NUTReplace.8 x 1.25 mm22 N.m {2.2 kgl.m, 16lbtfrl
Replace.8 x 1.25 mm16 N.m {1.6 kgI.m,12 tbf.ft)

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
,!

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

Inspection and Adjustment
Pump Belt
NOTE: When using a new belt, first adjust the deflection
or tension to the values for the new belt, then readjust
the deflection or tension to the values for the used beltafter running engine for five minutes.
Inspection
Attach the special tool to the belt and measure the ten-sion of the belt.
Tension:'99 -'00 mod€ls: B1642 Engin. Type onlyUsed Bsh: 390 - 540 N lao - 55 kgt.88 - 120 tbf)New Belt:740 - 880 N {75 - 90 kgf, 170 - 200 tbt}'96 - '00 models: Other Engine Types
Used Beh: 340 - 490 N (35 - 50 kgf, 77 - ilO tbflNew Belt:640 - 780 N 165 - 80 ksf, 1& - 176 tbf)NOTE:
. lf there are cracks or any damage evident on the belt,reDlace it with a new one.. Follow the manufacturer's instructions for the tensiongauge.
BELT TENSION GAUGE07JGG _ 001010A
Inspect the pump belt for cracks or any damage.Replace the belt with a new one if necessary.
Measuremont without Beh Tension Gauga:
Apply a force of 98 N (10 kgt,22 lbfl and measure thedeflection between the power steering pump and thecrankshaft pulleys.
Dsflectior:'99 -'00 model3: 816A2 Engine Typ€ ontyUsed Beh: 7.5 - 11.0 mm t0.30 - 0.43 inlNew Beh:5.0 - 7.0 mm (0.20 - 0.28 in)'96 - '00 models: Othor Engine Typos
Used Behi 10.5 - 14.0 mm (0.ial - 0.59 inlNow Beh:7.5 - 10.0 mm (0.30 - 0.39 inl
POWER STEERING PULUY
CRANKSHAFT PULLEY
17-32
Adiustment
1. Loosen the power steering pump mounting bolts.
2. Adjust the belt tension.
'99 - '00 mod€ls: 816A2 Engin€ Typo only
. Turn the adjusting bolt by hand to get the proper belttension, then retighten the mounting bolts,
ADJUSNNG BOLT
PUMP MOUNNNG BOLTS24 N.m (2.4 kgf'm, 17 tbtftlPOWER STEERINGPUMP
'96 -'00 modek: Othcr Engins Typos
. Pry power steering pump away from the engine witha wrench to get the proper belt tension, then retight-en the mounting bolts.
PUMP MOUNTING BOLT24 N.m (2,4 kgf.m, 17 lbl.ftl
PUMP MOUNTING BOLT24 N.m {2.a kgt m, 17 tbtftl
Start the engine and turn the steering wheel fromlock-to-lock several times, then stop the engine andrecheck the deflection of the belt,

A/G GomPressor Belt
Adjustment
Detlection Method
'1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/C compressor and the
crankshaft PulleY
A/C ComPressor Belt
Used Belt: 816A2 engine
6.0 - 9.5 mm 10 2'l - 0.37 inl
Except 816A2 engine
7.5 - 9.5 mm (0.30 - 0.37 in)
New Belt: 816A2 engine
4.5- 6 5 mm (0.18-0.26 in)
Except 815A2 engine
5.0-5 5 mm (0.20-0.26 inl
Note these items when adjusting belt tens'on:
. lf there are cracks or any damage evident on the
belt, replace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
tor less than five minutes.
2. Loosen, the center nut ofthe idler pulley (SANDEN), or
the pivot bolt of the idler pulley bracket and the lock
nut ofthe adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension'
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
5. Recheck the deflection of the A,/C compressor belt'
Tension Gauge Method
1. Attach the special tool to the IVC compressor belt as
shown below, and measure the tension of the belt
A/C Compressor Belt
Used Belt: 816A2 engine
390 - 540 N (40 - 55 kgf, 88 - 120 lbll
Except 816A2 engine
340 - 490 N (35 - 50 ksf, 77 - 110 lbfl
New Belt: B16A2 engine
?40 - 880 N {75 - 90 ksf' 170 - 200 lbf)
Except Bl642 engine
690 - 830 N (70 - 85 ksf, 150 - 190 lbf)
Note these items when adjusting belt tension:
. Follow the manufacturer's instructions for the
belt tension gauge.
. lf there are cracks or any damage evident on the
belt, rePlace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
for less than five minutes
2 Loosen the center nut of the idler pulley (SANDEN)' or
the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO)
5. Recheck the tension of the A/C compressor belt'
22-43