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To download a free repair manual, locate the model year you require above, then visit the page to view all available Honda Civic workshop manuals. We’ve checked the years that the manuals coverYou’ll then be shown the first 10 pages of this specific. Then you can clickSpam free: Maximum of 1 email per monthSpam free: Maximum of 1 email per month. We do however have a download limit of 3 PDF manuals per visitor, so ensure you download only the type of Honda manual you require for your car. You no longer need an account to download free PDF workshop manuals. We do however have download restrictions so please only download the PDF's you require. You no longer need an account to download free PDF workshop manuals. We do however have download restrictions so please only download the PDF's you require. You no longer need an account to download free PDF workshop manuals. We do however have download restrictions so please only download the PDF's you require. These books do not only give answers on how certain components have to be replaced or fixed but also gives information about the correct torque of each bolt and electric schematics. These manuals are available for many models such as the Civic Coupe, sedan and hatchback models. You can also find a lot of manuals for the CRX, Del Sol, S2000, Accord and Prelude models. Besides having a version of the repair manual at your disposal it can also be very useful to have a copy of a owners model for your car. These manuals give you information about certain features of the car but you can also find maintenance schedule and jack and tire replacement tips. We offer a useful link to most of these documents, you can find these documents here. It s divided into 24 sections. The first page of each section is market with a black tab that lines up with its corresponding thumb index tab on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents.
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The symbol printed at the top corner of each page can also be used as a quick reference system. Your comment must be approved by our moderators after sending it. Comment I accept the privacy policy. Ploase undorstand that these warnings cannot covsr all conceivable weys in which service.AnYono using. Fuel-injected Engine HONDA Passenger Serial Number vehicle Line, Body and Engine Type. Make and D16Y7: 1600 SOHC 16-valves Sequential Type of Vehicle Multiport Fuel-iniected Engine HONDA MOTOR CO., D16Y8: 1600 SOHC WEC 16-valves Sequentral LTD. MultiPort Fuel-injected Engine HONDA Passenger. Fuel-injected Engine HONDA passenger v e h i c l e 3 7 5 0 0 0 1 -: U. HONDA Passenger JAPAN: D16Y7 - 4700001- vehicle U.S.A: D'16Y7 - 4750001-. D16Y7: 1600 SOHC 16'valves HONDA Passenger Sequential MultiPort v e h i c l e Line. Body and Engine TyPe -. Sequential Multiport Fuel-iniected HONDA Passenger E n g i n e. Make and Engino Type Type ol Vehicle Bl642; 1600 DOHC WEC '16-vatves '1HG: HONDA OF AMERICA Sequential Multiport Fuel-injected t\4FG., tNC. E n g i n e HONDA Passenger D'I6Y5: 1600 SOHC WEC-E 16.vatves Vehicle. HONDA Passenger J a p a n: 5 7 0 0 0 0 1 - Vehicle U.S.A.: 5750001-. Always use safety stands whon working on or undel any vehicle that is supported by only a iack.Never tow the vehicle behind another vehi cle with iust a rope or chain lt is very dangerous' Emergency Towing There are three popular methods of towing a vehicle: Flat-bed Equipment - The operator loads the vehicle on the back of a truck. Each section in the manual that requires the use of special tools has them listed separately for that section. D i s c o n n e c t t h e I A T s e n s o r c o n n e c t o r, t h e n D16Y, ongino: remove the intake 8ir duct and air cleaner hous- Ing. Relieve fuel pressure (see section l1). 12. Remove the brake booster vacuum hose, fuel return hose and vacuum hose.
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Do not smoke while working on the fuel system, Keep open flame or spark away from the D16Y7 engine: wolk area. DrGYr, D16Y8 enginas: '18.Attach the chain hoist to the engine. HOISTING BRACKET Install on the cylinder head w i t h a 8 x 1. 2 5 m m b o l t. 5 - 1 0. R e m o v e t h e t r a n s m i s s i o n m o u n t b r a c k e t, t h e n remove the transmission mount. Install the transmission mount and bracket, then tighten the bolts on the frame side, NOTE;. The MIL has been reoorted on. DTC P1259 is sto.ed. Check the VTEC Cont.ol Syst6m: 1. Wire side of female Rcpai.Remove the cylinder head cover. NOTE: Reter to page 6-46 when installing the cylin- NOTE: Refer to page 6-46 when installing the cylin- der head cover. Before using th6 Valve Inspection Tool, make 3ure and connect the an air pressure regulator with a 0 - that ths air pressure gaugo on the air comptsssor 100 psi gauge. Visually check the disengagement of the synchro- Visually check the engagement of the synchronizing nizing pistons. Loosen the regulator valve on the valve inspection tool and apply the specified air pressure. U s e a 1 0 m m d i a m e t e r r o d t o d e p r e s s e a c h l o s t motion assembly through its full movement. R o t a t e t h e c r a n k s h a f t b r i n g N o. Using a downward motion on the lever arm, com- press the valve spring and remove the keepers from.press the valve spring and remove the keepers from t h e v a l v e s t e m. Mark the direction of rotation on the belt before removing.NOTE: Remove the upper cover (see page 6 19). Install the timing belt in the reverse order of removal; Only key points are described here.NOTE: Refer to page 6-46 when installing.ROCKEB ARM 6 x 1. 0 m m ASSEMBLY 12 N.m 11.2 kgf m, 8.7 lbf'ftl Femoval, page 6-30 Apply engine oilto the Inspection, Page 6-34 threads. D16Y8 engine: LOST MOTION 20 N.m 12.0 kgl.m, 14 tbf.ft) LOST MOTION ASSEMBLY Apply engine oit to the ASSEMgLY HOLDER threads. Do not smoke while working on tho fuel system.
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Ke6p opgn flame or gpark away from lhe 12. Remove the upper radiator hose' heater hose and the cylinder head.T h e b o l t s w i l l k e e p t h e holders, springs and rocker arms on the shaft. Rocker arms must be installed in the same position if reused.Do not rotate the camshaft during inspection.Zero the dial indicator against the end ofthe camshaft. 1. Remove the camshaft holders.As illustrated below, use a commercially-available air-impact valve guide driver attachment modified to fit the diameter of the valve guides. In most cases. the same procedure can be done using the special tool and a conventional hammer.Insert the valves NOTE: For new valve guides only.I n s t a l l t h e v a l v e s p r i n g a n d v a l v e r e t a i n e r.Tighten the cylinder head bolts sequentially in four Adjust the valve clearance (see page el2), steps.In the final 1 1. W h e n i n s t a l l i n g t h e c y l i n d e r h e a d c o v e r, h o l d t h e step, tighten all bolts, in sequence, to 9 8 N'm (1.0 head cover gasket in the groove by placing your fin- kgf.m, 7.2 lbf.ft). DTC P1259 is siored. Wire side of temale Ropair opon in the wiro batwoen terminals VIEC pr.urc switch and G lot. R e m o v e t h e V T E C s o l e n o i d v a l v e a s s e m b l y f r o m 1. R o t a t e t h e c r a n k s h a f t ' 1 8 0.Refer to page 6-59 for positioning crankshaft and pulley before installing belt. Mark the direction of rotation on the belt before removino.Only key points are described here. Remove the cylinder head cover' 1. Set the timing belt drive pulley so that the No. 1 pis' ton is at top dead center (TDC). Remove the back cover and camshaft pulleys. CYLINDER HEAD CAMSHAFT PLUG HOLDER PLATE Replace.S c r e w 1 2 m m b o l t s i n t o t h e r o c k e r a r m s h a f t s. Remove each rocker arm set while slowly pulling prevent them from separating. NOTE: ldentify parts as they are removed to ensure reinstallation in original locations.
Test it by pushing the plunger fully apply air pressure to the oil passage of the rocker with your finger, a r m. Removg the rocker arms and rocker shafts. Put the camshafts and camshaft holders on the cylin- der head.INTAKE EXHAUST lf the camshaft has not been replaced, first check 33.088 mm 32.785 mm PRIMARY. NOTE: ldentify valves and valve springs as they are removed so that each item can be reinstalled in its origi- VALVE GUIDE SEAL REMOVER nal Dosition.Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the 1. Coat both reamer and valve guide with cufting oil.In the first step, tighten all bolts in sequence to about 29 NOTE: N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten in. A l i g n t h e m a r k s o n t h e c y l i n d e r h e a d p l u g t o t h e 14. NOTE: Apply liquid gasket to the mating surfaces ofthe rightside coverand oil pumpcase before installingthem.Lubricate all internal parts with engine oil during PISTON INSTALLATION DIRECTION: reassembtv. Atter installation, tighten Remove the eight flywheel bolts, then separate the fly- the bolts in a crisscross Pattern.T o c h e c k m a i n b e a r i n g - t o - j o u r n a l o i l c l e a r a n c e.Clean them only with solvent ol code for the size of each of the 5 main journal bores. Clean them only with sol- C l e a n t h e c r a n k s h a f t r o d i o u r n a l a n d b e a r i n g h a l f vent or detergent, with a clean shop towel. Remove the oil screen. Remove the right side cover.Clean the crankshaft oil passages with pipe cleaners Out-of-Round and Tapet or a suitable brush.. Measure out-of-round at the middle of each rod. Check the keyway and threads.Alignment a The difference between measurements on each journal must not be more than the service limit. Check the piston for distortion or cracks, diameter (see page 7-16) and the piston diameter. N O T E: l f a c y l i n d e r i s b o r e d.Measure the diameter of the piston pin.
NOTE: Check the piston for distortion or cracks.Using a piston, push a new ring into the cylinder Using a ring expander.Clean all ring grooves thoroughly. Measure the piston ring end-gap with a feeler gauge: NOTE: lf the gap is too small, check to see if you have. After installing a new set of rings, measure ring-to- groove clearances: NOTE: The manufacturing marks must be facing upward.Apply a light coat of oil to the c.ankshaft and to MARK t h e l i p o f t h e s e a l.NOTE: Check clearance with plastigage (see page 7-9), then Use liquid gasket, part No. 08718 - 0001 or08718- tighten the bearing cap bolts in 2 steps. RIGHT SIDE Apply grease to the lips of the oil seals. Thgn, align the inner rotor with the crankshaft and i n s t a l l t h e o i l p u m p. Apply a light coat of oil to the crankshaft and io t h e l i p o f s e a l. 1. I n s t a l l t h e o i l p a n g a s k e t o n t h e o i l p a n. U s e n e w O - r i n g s a n d a p p l y o i l w h e n i n s t a l l i n g t h e m. Apply liquid gasket to the 1. A p p l y l i q u i d g a s k e t o n t h e o i l p u m p a n d r i g h t s i d e shaded areas. NOTE: a Use a new oil pan gasket.. I n s t a l l t h e o i l p a n n o m o r e t h a n f i v e m i n u t e s after applying liquid gasket. Using the special tool. drive the. Engine removal is not required.The crankshaft oil seal housing should be dry.NOTE: Use new O-rings when reassembling. Apply oil to O-rings before installation. Use liquid gasket, Part No 08718 - 0001 or 08718 - 6 x 1. 0 m m 0003. Park the vehicle on level ground, and turn off CAUTION: Removo the drain boli carefully while engine. Allow the oil a few minutes to drain back engine is hot; the hot oil may causo scalding.Be careful when loosening the drain bolt whils the engine is hot. It the oil level is cor- bers (1 to 8) are printed on the surface of the filter.Remove the oil jet (see page 8-3) and inspect it as follows. M a k e s u r e t h a t a 1. 1 m m ( 0.
0 4 i n ) d i a m e t e r d r i l l will go through the nozzte hole (j.2 mm (0.05 in) diameter). Use new O rings when reassembllng.. Apply oil to O-rings before installation. - 0003 Use liquid gasket, Part No. 08718 - 0001 or 08718. The rotors must be installed to the same direction in order' o After reassembly, check that the rolors move without binding' B15A2 engine: 6 x 1. U s e n e w O r i n g s w h e n r e a s s e m b l i n g.. Apply oil to O rings before instalraUon. U s e l i q u i d g a s k e t, P a r r N o. Check the housing-to-outer rotor radial clearance. 17. Reassemble the oil pump, applying thread lock to l f t h e h o u s i n g - t o - o u t e r r o t o r r a d i a l c l e a r a n c e the pump housing screws. Apply grease to the lip ot the oil pump seal. Install the oil pan (see pages 7-26 or 7-27). Then. install the oil pump onto the crankshaft. When the pump is in place, clean any excess grease NOTE: Clean the oil pan gasket mating surfaces. D16Y7 engine: 8 x 1.25 mm 22 N.m 12.2 kgtm, 16 tbtftl INTAKE MANIFOLD Replace if cracked or if mating surfaces are. D16Y8 engine: INTAKE MANIFOLD Replace if cracked or if mating surfaces are oamageo, INTAKE AIR CONTROL. Tighten the bolts in steps, alternatrng side-to-side. D16Y5, D16Y7 engines: D16Y5, D15Y7 engines: D i s c o n n e c t t h e p r i m a r y H O 2 S c o n n e c t o r, t h e n remove the cover. Dl6Y5, Dt6Y7 engines: 816A2 engine a. D i s c o n n e c t t h e s e c o n d a r y H O 2 S c o n n e c t o r.To avoid dangsr of rsleasing scalding tions of the body, rinse it off immediately.Remove the fan shroud assemblies and other parts from the radiator. R e m o v e t h e u p p e r a n d l o w e r r a d i a t o r h o s e s, a n d ATF cooler hoses. THERMOSTAT Install with pin up.Remove the timing belt (see section 6). T u r n t h e w a t e r p u m p p u l l e y c o u n t e r c l o c k w i s e. Remove the water pump by removing five bolts. O: Related to Fuel and Emissions System.
NorE: see the oBD ll scan tool or Honda PGM Tester user's manuals for specific operating instructions. Remove the ABS control unit if so as described below PCM bolt. Punqturing ihe insulation on a wirs can cause poor or intermiftent electricar connections. For temale connectors, iust touch lightly with the tester probe and do not inse.t the probe. The items Iisted in the table below conform to the sAE recommended practice. Vacuu m connection Manifold Absolute.Primary HO2S (Sensor 1) Primary Heated Oxygen Sensor (Sensor '1) Circuit ( 6 1 ) CKF sensor Crankshaft Speed (54i 1 1 1 8 3 P 1 3 3 6 Fluctuation Sensor Intermittent Interruption Crankshaft Speed CKF sensor (54) CKF sensor circuit 1 1 - ' 1 8 3 P1337 Fluctuation Sensor ECM,PCM. PGM-FImain relay. See the OBD ll scan tool or Honda PGM Tester user's manuals lor specitic operating instructions.Ropair short to body gtound in the wir. DTC P0107 is storod. MAP SENSOR 3P CONNECTOR IC1l1I Check for a short in ihe wire. The MIL has been reported on OTC m108 is stolod. DTC ml 08 b stolod. DTC P1128 is stored. Problem verification: 1. Turn the ignition switch ON (ll). 2. The IAT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases as shown below. The ECT Sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases as shown oetow. Chack for Door con- in Honda mode ol PGM Tester) or naction.The TP Sensor is a potentiometer.The TP Sensor is a potantiometer.The MIL has been reportod on. DTC P0123 is sto.ed. The MIL has been reported on DTC P0123 is slored. Problem verification: 1. The MIL hss been.eported on. DIC P1121 i. stored. Problem vedficatiod: 1. The MIL has been reported on. The scan tool indicates Diagnostic Trouble code (DTC) Pl163: A slow response problem in the Primary Heated I P 1 1 6 3 Oxygen Sensor (Primary HO2S) (Sensor 1)circuit.
The primary Ho2S (Sensor 1) is installed in the exhaust manifold. The MIL has beon reponed on. DTC P1164 is stored. Problem verification: 1. Ths MIL ha3 bcen r6port.d on. The MIL has beon reportod on. The MIL has been reported on. DTC P0139 is stored. The MIL has been lePorted DTC Pl166 b stored. Problem verilication: 1. DTC Pl167 i3 3tored. Problem Veritication: 1. Do the ECM Reset Procedure. 2. Description By monitoring the Long Term Fuel Trim, long term malfunctions in the fuel system will be detected.I P0304 I ths.rr tool indicates Diagnostic Trouble Code (DTC) PO3O4: Cylinder 4 misfire detected. Check the fuel iniecto.DTC PO:t25 is stored. The MIL has been reported on. DTC Pl106 is stored. Problem verification: 1.DTC P1607 is stored.After the engine starts, the lAc valve opens for a certain time. The amount about 150 - 300 rpm.The amount of When the coolant temperature is tow, the IAC valve is opened to obtain the bypassed air is thus controlled in relation to the engine coolant temperature' IOLE SPEED lrpml. NOTE: lf DTC P1508 or P1509 is stored at the same time as DTC P0505, troubleshoot DTC p1508 or p1bog first.The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in order to maintain the proper idle speed. The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in order to maintain the proper idle speed. Check the IAC valve fundion: Momentarily connect ECM con- nector terminals 823 and 82 with a iumpe. Inspection of Brake Switch Signal. Are the brake lights on without depressing the brake pedal. Depress the brake pedal. Are the brake lights on without depressing the brake Pedal.Inrpaction ot dutch rwitch signal.FUEL FILTER PRESSURE REGULATOR FUEL TANK FUEL GAUGE SENDING UNIT BASE GASKET R e p l a c e. C l a m p I n r h e m i d d l e C l a m p i n t h e m i d d l e 1 0 - 1 4 m m (0.39 - 0.55 inl.
ONBOARD REFUELING VAPOR BECOVERY IORVRI VENT SHUT VALVE FUEL lt N.rn l1.a kgt.m, GAUGE r0 lbt ftl ftr, n'fo'. Remove the 12 mm banjo bolt from the fuel filter while holding the fuel Jilter with another wrench Attach the special tools. EVAP PURGE CONTROL SOLENOID VALVE SEAL RING Replace. 7. Slide new cushion rings onto the fuel injectors. 8. Coat newO-ringswith clean engineoil, and putthem onthefuel injectors. 9. Keep open Do not smoke while working on luel sys- flamcs away from your work arsa. tem. Keep open flame away from your work area, 1. Attach the special tool(s) to the service port on the 1. Do not smoke whilc working on fuel system. Keep BOLT open flame away from your work arsa. 33 N.m. While replacing the tuel filter, be catelul to koep a (3.4 kgl.m, sale distance betwoen battery torminals and any 25 rbf.ftl tools. Keep open llames away from your work area.A resonator in the as air is drawn into the system. D16Y5, D16Y8 engins: LOCKNUT DEFLECTION ADJUSTING CABLE 1 0 - 1 2 m m BRACKET Bla- 112inl lf deflection is not within specs' loosen the locknut'. S e t t h e l o c k n u t o n t h e c a b l e b r a c k e t. A d j u s t t h e 816A2 engine: adjusting nut so that its free play is O mm. The lower portion ot the throttle valve is heated by engine coolant from the cylinder head' The idle adjusting screw which regulates the bypass air is located on the top of the throttle body IDLE AD.'USTING. Positive Crankcase Ventilation (pCV) system and The Three Way Catalytic Converter (TWC) is used to Evaporative Emission (EVAP) Control system. EGR vacuum conrrot vatve. EGR control solenoid valve. Doscription the changes in MAP before Deterioration (clogging, leakage, etc.) in the EGR line or EGR valve is detected by means of and after the operation of the EGR valve. H o l d t h e engine at 3,000 rpm with no load (transmission in neutral) untilthe radiator fan comes on. The MIL has been reportod on. DTC P1498 is storod.
R e c o n n e c t t h e E V A P p u r g e control solenoid valve 2P con- nector. InsDect vacuum ho56 routing.ChGck tor an opon in lho wite 3. The scan tool indicates Diagnostic Trouble Code (DTC) P1457: Evaporative Emission (EVAP) control system leak tP14sz-l detected (EVAP control canister system). Insped vacuum hose routing. lf OK. Remove the fuel fill cap. Remove the fuel fill cap to relieve the fuel tank pres- Remove the fuel hose joint protector. Remove the fuel tank (see page 1 1-242). Remove the ORVR vent shut valve from the fuel tank. A973X - 041 - xxxxx Apply vacuum (1 pump) to the ORVR signal hose,. Inspection Replacement.12-9 Clutch Disc, Pressure Plate 12-10. Remove the slave cylinder from the clutch housing. Using a non-Honda brake fluid can cause corro- sion and decrease the life of the system. Inspect the fingers of the diaphragm spring for wear a n d b u r n i n g.Inspect for warpage using a straight edge and leeler Check the diaphragm spring fingers for height using g a u g e. Inspect the ring gear teeth for wear and damage I n s p e c t t h e c l u t c h d i s c m a t i n g s u r f a c e o n t h e FLYWHEEL flywheel for wear, cracks, and burning. I n s t a l l t h e s p e c i a l t o o l.Disconnect the connector, then remove the back-up light swirch connector from the connector clamp. 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.Remove Remove the driveshafts (see section 161.NOTE: Coat all the precision finished surfaces with clean engine oil or grease. Tie plastic bags over the SI'IIFT BOD driveshaft ends, SET RING 1 0 x 1. R e m o v e t h e t h r e e u p p e r t r a n s m i s s i o n m o u n t i n g bolts and the lower starter mounting bolt, removal. N O T E: U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e 'l.25 mm O 1 2 x 1.
Install the angular ball bearing with the thin-edge outer race facing the sth synchro hub.NOTE: Refer to page 13-15 for reassembly sequence.Snap ring groove faces up. NOTE: lf replacement is required, always replace the synchro sleeve and hub as a set. 0.04 - 0.12 mm (0.002 - 0.005 in) Standard: Servico Limit: 0.2,1 mm 10.009 in) 1. Use of a iaw-type puller can damage tershaft out of 5th and 4th gears as shown.Press the 3rd,4th, and sth gears on the countershaft countershaft w e a r a n d d a m a g e, t h e n m e a s u r e t n e without lubrication. SYNCHRO A: Inspect the inside of the synchro ring for wear. B: Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off).OIAL THRUST SHIM Selective part BALL BEARING Check for wear and damage. DIFFERENTIAL C h e c k l o r c r a c k s. SPEEDOMETER DRIVE GEAR FrNAL DRTvEN. NOTE: Do not apply liquid gasket to the mating sur- face of the clutch housing. D16Y8 engines lf the clearance is more than the standard, select a new thrust shim from the following table Thickness Part Numbel NOTE: It the clearance measured in step 6 is within 1. 0 m m ( 0. 0 3 9 4 i n ) 41441 - PL3 - B00 the standard. Thickness Part Number 23931 - PL3 - 800 0.60 mm 10.0236 in) 0.63 mm (0.0284 in) 2 3 9 3 2 - P L 3 - 8 0 0 0.66 mm (0.0260 in) 2 3 9 3 3 - P L 3 - 8 0 0 0.69 mm 10.0272 in) Insert shift arm shaft in the clutch housing. Install the collar, spring.Compress the ball and insert the shift arm shaft, Set shift arm A on the clutch housing, then install Install shift arm C in shift arm A, then insert the shift the shift rod. Position the 36 mm spring washer and washer onto 15. Install the mainshaft, countershaft, and shift fork GEAR assemblies. Lower the transmission housing with the snap ring pliers, and set the snap ring into the groove of the OIL GUTTER PTATE countershaft bearing. NOTE: Check that the snap ring is securely seated in the groove of the countershaft bearing 32 mm SEALING EOLT 25 N.m (2.5 kgf.
m, 18lbf.ftl. I n s t a l l t h e b a c k - u p l i g h t s w i t c h a n d t r a n s m i s s i o n t h e n u m b e r e d s e q u e n c e i n s e v e r a l s t e p s s h o w n hanger. I n s p e c t r u b b e r p a r t s f o r w e a r a n d d a m a g e w h e n d i s a s s e m b l i n g; r e p l a c e a n y w o r n o r d a m a g e d p a r t s.. NOTE: Check the oil with the engine OFF.Disconnect the connector, then remove the back-up light switch connector from the connector clamp. Remove the oil filler plug, then check the level and condition of the oil. Make sure iacks and safoty stands are placad plop- erly (3ee section l). Disconnect the starter motor cables and the vehicle speed sensor (VSS) connector. Apply parking braks and block rear wheels so car will not roll off stands and fall on you while working under il. Remove the driveshafts and the intermediate shaft 17. Remove the front and the rear engine stiffensrs. (see section 16). NOTE: Coat all precision the finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends, 1 5. Remove the right front mounvbracket.Clean all the parts thoroughly in solvent and dry with compressed air.Standard: Remove the 72 mm thrust shim and the oil guide Revsrs. Measure the clearance between the shift piece and the interlock.Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in) 0.05 - 0.35 (0.fi)2 - 0.014 inl Standard;. Measure the clearance between the select arm and piece and the interlock.CLUTCH HOUSING NOTE: Tape the mainshaft spline before removing the mainshaft and the countershaft assemblies. Remove the spring washer and the washer' MAINSHAFT COUNTERSHAFT. NOTE: Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4th and 5th gears.M e a s u r e t h e c l e a r a n c e b e t w e e n t h e 1 s t g e a r a n d M e a s u r e t h e c l e a r a n c e b e t w e e n t h e 2 n d a n d 3 r d gears.
S e c u r e l y c l a m p t h e c o u n t e r s h a f t a s s e m b l v i n a Remove the bearing outer race, then remove the bench vise with wood blocks. I n s t a l l t h e s y n c h r o s p r i n g.A: Inspect the inside of the synchro ring for wear' SYNCHRO RING B: Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). GOOD WORN C: Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off). M e a s u r e t h e b a c k l a s h o f b o t h p i n i o n g e a r s.NOTE: Do not apply liquid gasket to the mating sur- face of the clutch housing. Beplace the 80 mm shim selected in step 7, then Standard: 0 - 0.10 mm (0 - 0.004 inl recheck the clearance. Use a straight edge and depth gauge.. Check the thrust clearance in the manner described c. Seat the mainshaft fully by tapping its end with a oetow.Install the shift rod Install the steel ball' the spring, and the set screw' Install the spring washer and change piece attach- ing bolt. Install the shift rod boots. 8 x 1. Install the spring pin and the clip on the change joint as shown'. Turn the shift rod boot so the hole is facing down as shown' Make sure the shift rod boot is installed on the shift rod' I x 1.25 mm 22 N.m 12.2 kgf.m, 16 lbf.ft) Torque Convertel, Geats, and Clutches The torque converter consists of a pump, turbine and stator, assembled in a single unit. They are connected to the engine crankshaft so they turn together as a unit as the engine turns. All clutches released. E REVERSE Reverse;. The one-way clutch locks up when power is transmitted from the mainshaft 1st gear to thetountershaft 1st gear. Power is not transmifted to the countershaft. E Position Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear. TOROUE CONVERTER rST CLUTCH COUNTERSHAFT.
Hydraulic pressure is applied to the 2nd clutch on the mainshaft, and power is transmifted via the 2nd clutch to the mainshaft 2nd gear. Powet transmitted to the mainshaft 2nd gear is conveyed via tho countorshaft 2nd gear, which drivos the counter- shaft. Power from the mainshaft 3rd gear is transmitted to the countershaft 3rd gear. Power is transmitted to the final drive gear, which drives the tinal driven gear. NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of 3rd gear exceeds that of 1st gear, power from lst gear is cut off at the one-way clutch. Power is transmitted to the countershaft 4th gear' which drives the countershaft' Power is transmitted to the final drive gear, which drives the final driven gear' gear exceeds that of 1st NOTE: Hvdraulic pressure is also applied to the lst clutch, but since the rotation speed of 4th gear, power from 1st gear is cut off at the one-way clutch. The reverse shift fork engages with the reverse selector, reverse selector hub, and the countershaft reverse gear. The primary functions of the main valve body are to swatch fluid pressure on and off and to control the hydraulic pressure going to the hydraulic control svstem. The fluid from the ATF pump flows through B and 8,. The line pressure (1) is regulated charged into (1). Then, ATF flowing from the ATF pump becomes the line (92) enters (94) of the torque converter through the lock-up by the regulator valve. The line pressure (1) changes the trne pressure (4) and (25) at the manual valve.Shift control solenoid valve A remains ON. The modulator pressure (6) flows to the right end of the 1-2 shift valve and the left end oJ the 2-3 shift valve. The modulator pressure (6) flows to the left end of the t-2 shift valve and the left end of the 3-4 shift valve. The iine pressure (Reverse range position) and uncovers the port to and flows to the servo valve.