out HONDA CIVIC 1996 6.G Repair Manual

4.
Removal/lnspection/lnstallation
2.
3.
1.
5.
6.
1.
8.
Drain the engine oil.
Turn the crankshaft and align the white groove on
the crankshaft pulley with the pointer on the lower
cover.
Remove the cylinder head cover and upper cover'
Remove the power steering pump belt, air condi-
tioner beit and the alternator belt
Remove the crankshaft pulley and remove the lower
cover.
Remove the timing belt.
Remove the drive pulley.
Remove the oil pan and oil screen.
O.RINGReplaceOOWEL PIN
OIL SCREEN
9. Remove the oil PumP.
!'a
10.Remove the screws from the pump housing, then
separate the housing and cover'
Check the inner-to-outer rotor radial clearance on
the pump rotor. lf the inner-to outer rotor clearance
exceeds the service limit, replace the inner and
outer rotors.
lnner Rotor-to-Outer Rotor Radial Clearance
Standard {New}: 815A2 engine 0.04 - 0.16 mm
(0 002 - 0'006 in)
D16Y5, D16Y7, D16Y8 engines
0.02 - 0.14 mm 10.001 - 0.006 in)
Service Limit: 0.20 mm (0 008 inl
OUTER ROTOR
INNER ROTOR
Check the housing-to-rotor axial clearance on the
pump rotor. lf the housing-to rotor axial clearance
exceeds the service limit, replace the set of inner
and outer rotors and/or the pump housing
Housing-to-Rotor Axial Clearance
Standard (N€w): 816A2 engine 0.02 - 0.07 mm
(0.001 - 0.003 inl
D16Y5, D16Y7, D16Y8 engines
0.03 - 0.08 mm (0.001 - 0.003 inl
S€rvice Limit: 0.15 mm 10.006 in)
11.
't2.
(cont'd)
8-13

Oil Pump
RemovaUlnspection/lnstallation (cont'dl
13. Check the housing-to-outer rotor radial clearance.lf the housing-to-outer rotor radial clearanceexceeds the service limit, replace the set of innerand outer rotors and/or the pump housing.
Housing-to-Outer Rotor Badial Clearanco:Standard {Newl: 816A2 sngine 0.10 - 0.19 mm(0.004 - 0.007 in)
D16y5, Di6y7, Dt6y8 engines0.10 - 0.18 mm {0.00it _ 0.007 in)Service Limit: 0.20 mm (0.008 in)
lnspect both rotors and pump housing for scoringor other damage. Replace parts if necessary.
Remove the old oil sealfrom the oil pump.
Using the special tool, gently tap in the new oil sealuntil the driver bottoms against the pump.
NOTE: The oil seal alone can be replaced withoutremoving the oil pump.
DRIVER ATT52x55mm077a6 - 0010ao0
14.
15.
16.
8-14
PUMP HOUSING
17. Reassemble the oil pump, applying thread lock tothe pump housing screws.
18. Check that the oil pump turns freely.
19. Apply a light coat of oilto the seal lip.
20. Install the two dowel pins and new O-ring on the oilpump.
21. Apply liquid gasket to the cylinder block mating sur_face of the oil pump.
NOTE:
. Use liquid gasket, Part No.08718 - oOOj or 08718- 0003.. Check that the mating surfaces are clean and drybefore applying liquid gaskel. Apply liquid gasket evenly, in a narrow bead cen-tered on the mating surface.o To prevent leakage of oil, apply liquid gasket tothe inner threads of the bolt holes.. Do not install the parts if five mtnures or morehave elapsed since applying liquid gasket.Instead. reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
81642 engine:
\
D16Y5, D16Y7, D16Y8 engines:
along the broken line.

Bt6A2, Dl6Y8 engines:
a. Disconnect the primary HO2S connector then
remove the primary HO2S.
816A2 engine
D16Y8 engine
PRIMARYH02S CONNECTOR
PRIMARY HO2S44 N.m {4.5 kgt'm.33 lbf'ft)
L
2. Install the primary HO2S in reverse order of removal'
Secondsry H02S:
1. Remove the secondary HO2S
Dl6Y5, Dt6Y7 engines:
a. Disconnect the secondary HO2S connector.
then remove the secondary HO2S'
02 SENSOR
816A2, Dt6Y8 ongin6s:
a. Remove the grommet, and pull out the secondary
HO2S connector, then disconnect the secondary
HO25 connector'
SECONOARY H()2S
CONNECTOR
{cont'd)
9-13

lllustrated Index
@@ system is under high pressure when theengine is hot. To avoid dangsr of rsleasing scaldingengine coolant, removo the cap only when the engine iscoot.
Total Cooling System Capacity flncluding heater andfoservoir (0.4 f (0.42 US qt, 0.35 tmp qt)ll:
*2: 81642 engine*3: D16Y7 engine*4: D16Y8 engine
CAUTION: lf any engine coolant spills on painted por-tions of the body, rinse it off immediately.
NOTE:
. Check all cooling system hoses for damage, leaks ordeterioration and replace if necessary.. Check all hose clamps and retighten if necessary.. Use new O-rings when reassembling.
RADIATOR CAPPressure test, page '10 86x1.0mm9.8 N.m {1.0 kgtm,7.2 tbt.ltl
UPPERRADIATORHOSE
UPPER BRACKETAND CUSHION
COOLANT
RAOIATOREngine coolant refilling and bleeding,page 10 7Leak test, page 10-9Inspect soldered joints andseams for leaks,Blow out dirt Irom betweencore fins with compressed air.lf insects, etc,, are cloggingradiator, wash them off withrow pressure water.
RESERVOIR
5x0.8mmA: ,1.4 N.m {0.45 kgf.m, 3.3 tbtftlg: 5.4 N.m (0.55 kgtm.4.0 tbf.ft)
6x1.0mm7.2 N.m (0.73 kgt.m,5.3 tbtftl
LOWERCUSHION
RADIATOR FANBADIATORFAN
DRAINPLUG
O-RINGReplace.
LOWEBRADIATORHOSE
FAN MOTOR SHROUD
Ar TOYO RADIATOR manufactured radiatorB: NIPPONDENSO manufacfared raoraror
10-2
Refer to section 14when installing.
Mt-|-4.2 f (4.4 US qt,3.7 tmp qt)*j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
4.1 f (4.3 US qt, 3.6 lmp q0*3
4.31 (4.5 US qt, 3.8 tmp qt)*a
CVT4.3 f (4.5 US qt,3.8 Imp qt)
*1i D16Y5, D16Y7, D16Y8 engines
iil

EGT Switch
-f
Testing
Replace the thermostat if it is open at room temperature'
To test a closed thermostat:
1, Suspend the thermostat in a container of water as
shown.
THEBMOMETER
THERMOSTAT
Heat the water, and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open
CAUTION: Do not let the thermometer touch the
bottom of the hot Gonlainel.
Measure lift height of the thermostat when fully
open.
STANDARD THERMOSTAT
Lift height above 8.0 mm (0.31 inl
Starts opsning: 169' - 176'F (76' - 80'Cl
Fully open: 194'F {90"C1
!'o
10-1 1
Testing
!!@ Romoving the EcT swhch while lhs engine
i!-ot can cause the coolant to sPray out, seriously scald-
ing you. Always lst th€ ongine and rediator cool down
before removing ihe ECT switch.
NOTE: Bleed air from the cooling system after installing
the ECT switch (see Page 10-7)
1. Remove the ECT switch from the thermostat hous-
ing (see Page'10-10).
2. Suspend the ECT switch in a container of water as
shown.
Heat the water, and check the temperature with a
thermometer.
CAUTION: Do not let the thermomoter touch tho
bottom of the hot container'
Measure the resistance between the A and B termi-
nals according to the table.4.
Terminal
Oo"rffi
swlTcH
ON196' - 203"F
(91" - 95'C)o--o
OFF
5" - 15'F {3" - 8'C)
lower than the temPera-
ture when t goes on

Water Pump
lllustrated Index
NOTE:
. Use new O-rings when reassembrrng.. Use liquid gasket, Part No. 08718 - 0OOl or 087 t8 _ 0003.
O16Y5, D16Y7, D16Y8 engines:
ECT GAUGESENDING UNIT9 N.m {0.9 kgI.m,7 tbnftlApply liquid gasketto the threads.
ENGINE COOLANTTEMPERA TURE (ECT)SENSOR1E N.m (1,8 kgf.m,13 rbttt)
6x 1.0 mm9.8 N.m {1.0 kgf.m,7.2 tbt.ft'|
O.RINGReplace.WATER OUTLETCOVERApply liquid gasketto mating surface.
ECT SW1TCH24 N.m 12.4 kgf.m,17 rbf.ftl
6xl.0mm12 N.m {1.2 kgf.m,8.7 tbf.ft)
6x1.0mm'12 N.m {1.2 kgt m,8.7 lbt fr)
10 x 1.25 mmitl N.m 14.5 kgt m,33 rbf.ftlO.RINGReplace.
10-12

815A2 engine:
WATER OUTLETCOVERApply liquid gasket
to mating surface.
6x1.0mm9.8 N.m {1.0 kgl'm,7,2 tbl.ftt
ECT GAUGESENDING UNIT9 N.m (0,9 kgf.m,7 rbf.ft)Apply liquid gasket
to the threads.
rENGINE COOLANTTEMPERATURE (ECT)
SENSOR18 N.m {1.8 kgf.m,13 tbtftl
6x1.0mm12 N.m (1,2 kgd m,
8.7 tbf.ftl
16@
aY@
t"S X 1.0 Mrf WATEN PUMP
iiil:i'iij rnr.., Inspection, pase 10'1'r
8.7 tbf.ftl
\lo
10-13

System Connectors [Fuel Pumpl
'95 - 98 models, '99 - 00 Dl6Y5 engine with M/T:
ffi
c565
E
c792*r,.'5c793|.,.s
*1r USA mod€l'2: A/T {O16Y7, D16Y8 ensine}13: CVT {O16Y5 ensin€l*4: A/T ind D16Y7 .ngane*5: ExceFt A/T end D16Y7 engine'6: A/T lDl6Y8 enginel*7: CvT (Dl6Y5 enginoland 016Yg engine'8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine
{coupe: sll models, s€d.nr KL modell,'98 Dl5Y5.ngine,'98 D16Y7 engine,'99 - OO Dl6Y5 (M/Tl enginer9: D16Y5 onginet10: M/T {D15Y5 ensinelr1t: ExceDt M/T (D16Y5 engine)tl2: D16Y5, Dl6Yg engine*13: Dl6Y8 enginer14: D16Y7 engine*15:'97 Dl6Y7 ensine {coupe: KL model, sodan:
KL (LX) modeu,'98 Dt6Y7 engine
NOTE: . Different wires with the same color have been given a number suffix to distinguish them (for example' YEUBLK1
and YEVBLK' are not the samel.
. O: Related to Fuel and Emissions System'
. - Connector with male terminals (dou ble outline): View f rom term inal side
- Connector with female terminals (single outline): View from wire side
c7931...15
ffi
1 1-51

Cl0,r{C.nadal
r'fr]
l6mrrrnru IElilrwA----llTltHtBtu__l
:lo.
l'lrl
lrl.l
c109..
r'frtr
16lonl -l
l@LYEUBLK' Ibfgl-rcgtu'---l
c102
r'Trtt
l6lwtr,eED' _-l
E|BFIvBLK -l
l6lga-tnEcl--l
c105
Etr
c106
ffi
c114
fr
c108
ffi
c107
ffi
Bffiffi
c113*1
ffiffi
,DGRN/BLK'(9LT GRN?BLU]38
NOTE: . Different wires with the same color have been given a number suffix to distinguish them (for 6xample, YEUBLK1
and YEUBLK'are not the same).
. O: Related to Fuel and Emissions Syst€m'
. - Connector with male terminals (double outline): View from terminal side
- Connector with female terminals (single outline): View trom wire side
(cont'd)
11-53
c1a2.r
fr

c1t7
r'ffi]
f'TBLir-llO BLX,YEI Il6lEtu^tHr__-l
c125
ffi
16lwrrin+o' tliSlcFN/BLK I16T8LK^'Er-- l
-.,IBaK,r /Hr. I
c141*'
___l:t_
l-lrl
I ' LT GRNA/VHT I
f€,]-BLK,rEf-__l
cl16c1t5cl11
c128.'
ffi
1618r-uf/EL-_]
161-cfl,avHr -l
cl45rrc
Ft_
l-,T,ITd
t_-Ttli I
c127*'
fr
IFFEc'--__l
ftlwHn-'_l
-c,1*
t-El-rl1 I 2l 3l
l.l
'ul
16lvvrrr/BtK---.llglcnN/BrK, IlO YEvBru I16r lsrK' IET- --
f+plr-, -_l
c118"
ffi
trl-clrl---]latl IBLU, I
c126*'
ffi
fOTwHn-_-llOlREo. I
:.trn
.EL
[tT,l.l
v
I i wHl/8tK IlETc RNi BLF--l
ET-YtrrrruBiu-__-l
q]54't
r,f,"|
I i IBLK4/VHT IlOlsLK I
IO LGRN/RED I
c112
fr
c120
tdl cnN/YEt--l
NOTE: . Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLK'
and YEUBLIC are not the same).
. O: Belated to Fuel and Emissions System'
. - Connector with male terminals (double outline): View from terminal side
- Connector with female terminals (single outlins): View from wire side {cont'd}
c121*'
ffi
c123
ffi
c1a0rt
fr
l6lgrf,---_-lIOIREB I
c13!,.f
E
c122
iYEUGFNoBLU5REO!8L(,
YEL'98tu
510BLK/YEL
c351
1 1-55