1999 HONDA CIVIC ac line

16. Install a new set ring on the end of each driveshaft'
17. Installthe right and left driveshafts (see ssction 16)
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor for-
eign particl€s to enler into the transmission.
NOTE:
. Clean the areas where the driveshafts contact the
transmission (differential) thoroughly with sol-
vent or carburetor cleaner, and dry with com-
pressed air.
. Turn the right and left steering knuckle fully out-
ward, and slide each driveshaft into the differen-
tial until you feel its set ring clip engage the side
gear.
18. Install the damper fork, then install the rightand left
ball joints to the each lower arm with the castle nuts
and new cotter Plns.
DAMPER PINCH BOLT
10 x 1 .25 mma3 N.m l4.ia kgf.m,
32 tbl.ftl
4l
COTTERReplace.SELF.LOCKING NUT
12 x 1.25 mm
6il N.m t6.5 kgf'm, il7 lbf ftl
Replace.
19. Install the splash shield.
{5.0 - 6.0 kgf m, 36 - iB lbf'ft|
CASTLE NUT12 x 1,25 mm49 - 59 N.m
20. Connect the mainshaft speed sensor, the linear sole-
noid and the shift control solenoid connectors.
SHIFT CONTROL SOLENOIO LINEAR SOITNO|o
CONNECTOR CONNECTOR
6 r 1.0 mrn12 N.m (1.219f.m,
E.7 lbf.frl
CONNECTOR
21. Connect the countershaft speed sensor and the vehi-
cle speed sensor (VSS) connectors.
VEHICI..E SPEED
SENSOR CONNECTOR
COUNTERSHAFTSPEED SENSORCONNECTOR
(cont'dl
14-185

Cooler Flushing
!!!@ To prevent iniury to. face and eyas, always
-ea. safetv glasses ot a face shield when using the
transmission flusher.
NOTE: This procedure should be performed before rein-
stalling the transmission.
1. Check the tool and hoses for wear and cracks before
using. lf wear or cracks are found, replace the hoses
before using.
Using the measuring cup, fill the tank with 2'l ounces
(approximately 2/3 full) of biodegradable flushing
fluid (J35944 - 20). Do not substitute with any other
fluid. Follow the handling procedure on the fluid
contarner.
Secure the flusher filler cap, and pressurize the tank
with compressed air to between 550 - 829 kpa (5 6 -
8.45 kgflcm'. 80 - 120Psi).
NOTE: The air line should be equipped with a water
trap to ensure a dry air system.
Hang the tool under the vehicle.
Attach the tank's discharge hose to the return line
of the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-
mission cooler using a clamP
IMPORTANT:
Securely clamp the opposite end oJ the drain hose to a
bucket or floor drain.
TRAMtssroN
TRANSMISSION COOLERFLUSHER{Commcrci.llY avail.blel
Kent-Moore J384O5'Aor equivelent
NS
I
{r Water
7. With the water and air valves off, attach the water and
air suDolies to the flusher' lHot water if available.)
8, Turn on the flusher water valve so water will flow
through the cooler for 10 seconds.
NOTE; lf water does not tlow through the cooler, it
is completely plugged. cannot be flushed, and must
be replaced.
9. Depress the trigger to mix the flushing fluid into the
water flow. Use the wire clip to hold the trigger down'
While flushing with the water and flushing fluid for
two minutes, turn the air valve on for five seconds
everv 15 - 20 seconds to create a surging action'
AIR PRESSURE: MAX 845 kpa {8.45 kgf/cm', 120 psi)
Turn the water valve off. Release the trigger, then
reverse the hoses to the cooler so you can flush in
the opposite direction. Repeat steps 8 through 10'
12, Release the trigger, and rinse the cooler with water
onlv for one minute
13. Turn the water valve off, and turn off the water supply
14. Turn the air valve on to dry the system out with air
for two full minutes or until no moisture is visible
leaving the drain hose.
CAUTION: Residual mobturo in tho cooler or pipas
can damage the transmksion'
15. Remove the flusher from the cooler line. Attach the
drain hose to a contalner.
16. Install the transmission, and leave the drain hose
attached to the cooler line
{cont'd)
10.
'11.
14-187

Transmission
17.
Cooler Flushing (cont'dl
Make sure the transmission is in the E position.
Fill the transmission with ATF, and run the enginefor 30 seconds or until approximately 0.95 f (1.0 USqt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the coolerreturn hose to the transmission (see page l4-192).
Refill the transmission with ATF to the oroDer level(see page 14-118).
18.
19.
b
14-18A
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with waterand pressurize the can. Flush the discharge line toensure that the unit is clean.
2. lf discharge liquid does not foam, the orifice may beblocked.
3. To clean, disconnect the plumbing from the tank atthe large coupling nut.
ORIFICE
GRT{G
Remove the in-line filter from the discharge side andclean if necessary.
The fluid orifice is tocated behind the filter.Clean it with the pick stored in the bottom of thetank handle, or blow it clean with air. Securelvreassemble all Darts.
FILLER CAP

Shift Indicator PanelATF Cooler Hoses
Adiustment
'1.Check that the index mark on the indicator alionswith the N mark on the shift indicator panel whenthe transmission is in NEUTRAL.
3 N.m {0.3 kgf.m, 2lbt.ftl
lf not aligned. remove the front console {see section20t.
Remove the shift indicator panel mounting screwsand adjust by moving the panel,
NOTE: Whenever the shift indicator panel is removed,reinstallthe panel as described above,
INDEX MARK
L
14-192
Connection
1. Connect the ATF cooler hoses to the ATF cooler linesand ATF cooler, and secure them with the clips asshown.
TRANSMISSION CLIP

Continuously Variable Transmission (CVTI
Special Tools ................ 14-194
Description .................... 14-195
Clutches/Reverse Brake/Planetary
Gear/Pulleys .......... 14-198
power Flow ..............,..... 14-200
Electronic Control SYstem(,96 - 98 Modets) ......14-203
Electronic Control System
('99 - oo Models) " 14-205
Hydraulic Control '....... 14-208
Hydraulic Flow .'..-.....'... '14-212
Park Mechanism .....-...'.' 14-222
Eleqtrical Systom
Component Locations'96 - 98 Models """"""' 14-224,99 - 00 Modets ............. 14-225
TCM Circuit Diagram ('96 - 98 Models) ............. 14-226
TCM Terminal Voltage/Measuring Condiiions ('96 - 98 Models) '.... 14-228
PcM Circuit Oiaqram{A/T Control System: '99 - 00 Models} ...--.... 14-230
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)
A/4 Control System .'.'...14-232
Troubleshooting Procedures ... . .... .....',........."' '14-234
Symptom-to-ComPonent Chart
Electrical System - '96 - 98 Models ......'..... '14-234
Electrical System -'99 - 00 Models ..'....-..-. '11-210
Electrical Troubleshooting
Troubleshooting Flowcharts('96 - 98 Models) """'11-242
Troubleshooting Flowchart
('99 - 0O Modets) ...... 14-265
Linear Solenoids/lnhibitor Solenoid
Test ......................... . ...... 14-29f
Drive Pulley/Driven Pulley/Secondary Gear
Shaft Speed Sensors
Replacement .........'...... .14-292
Start Clutch Control
Start Clutch Calibration Procedure ....... ....,. 14-293
Hydraulic SYstem
Symptom-to-ComPonent Chart
Hydraulic System '.'.......14-294
Road Test ............................ 14-296
Stall Speed
Test......................... ...... 14-294
Fluid Level
Checking/Changing ....... 14-299
Pressure Testing ................. 14-300
Lower Valve BodY AssemblY
Replacement ..........,... 14-302
ATF Filter
Removal/lnstallation ..... 14-303
Transmission
Transmission
Removal ........... . 14-304
lllustrated Index
Transmission/Lower Valve BodY
Assembly ................. 14-308
Transmission Housing/Flywheel Housing ... 14-310
End Cover/f ntermediate Housing ..........'.'.... 14-312
Transmission Housing/Lower Valve Body Assembly
Removal ..........'.... .. " 14-314
Transmission Housing/Flywhesl Housing
Removal ................. ........ 1+316
End Cover/lntermediate Housing
14-318Removal .........,...............
Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'..... 1 4-320
Forward Clutch
lltustrated Index ........................................ 14-321
Disassemblv .................. 14-322
Reassemblv , ,, . ',','......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection ..'.'....-... 14-324
Differential
lllustrated lndex ...,.....................,.,...-.-.-...'... 14-329
Backlash Inspection .-....14-329
Bearing Replacement ......'........'....'... ....'... 14-330
Differential Carrier Replacement ........'........ 14-330
Oil Seal Removal ........... 14-331
Oil Seal Installation/Side Clearance ....... . . 14-331
Flywheel Housing Input Shaft Oil Seal
Replacement .....,.... ...'.'.. 14-333
Transmission Housing Bearings
Driven Pulley Shaft Bearing
Replacenient ...................'. . ...................'.. 14-334
Secondary Gear Shaft Bearing
Reolacbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Secondary Gear Shaft BearingReo1acement..................,........................... 14-335
Ring Gear Bearing
Replacement......... ........ 14-336
Control Shaft Assembly
Removal/lnstallation ....................'........... 14-336
Transmission
Reassembly .................. 14-338
Flywheel/Drive Plate .. . ...... . ...... ... . ....-.....'.'...14-341
Transmission
lnstalation ..................... 14-348
Cooler Flushing .'......... 14-352
shift cable
Removal/lnstallation....'........." """ 14-354
Adjustment .......'........ 14-355
Shift Lever ........................,. 14'356
Shift Indicator Panel
Adjustment ................ 14-357
ATF Cooler/Hoses
lnsta llation ......,,...... .... 14-357

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

Electronic Control System ('96 - 98 Modelsl
The electronic control system consists of the Transmission control Module (TcM), sensors, three linear solenoids, and an
inhibitor solenoid. Shifting is electronically controlled under all conditions
The TCIM is located below the dashboard, behind the kick panel on the driver's side'
The TcN4 controls the transmission to reduce engine speed and retain the engine's cooling efficiency when the vehicle is
driven with Iull throttle acceleration
lf the vehicle is continuously driven at full throttle acceleration, the TCM regulates the pulley hydraulic pressure to
increase the pulley ratio, which, as the result. reduces the engine speed and retains the designed cooling efficiency After
the vehicle has been driven at a lower engine speed for a while, the TCM increases the pulley ratio to the original ratio.
For smooth starting in the E position, the TcM sends a signal to the EcM to cut off the rvc clutch {if the A!/c is on) and
increases the engine speed to 900 rpm when the transmission is shifted to the E position'
The start clutch functions to make smooth starting possible. To let the start clutch function properly. the TCM regulates
the start clutch hydraulic pressure based on the entine's negative pressure memorized in the E position'
:
:
z
z
z
S*ond.ry G..r Sh:ft
(cont'd)
14-203