Rocker assembly HONDA CIVIC 1996 6.G Workshop Manual

Cylinder Head/Valve Train
Dl6Y5, D16Y7, Dl6Y8 engines
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection ............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5 engine) ............................. 6-7
Manual Inspection
(D16Yg enginel ................'............ 6-7
Inspection Using Special Tools
{D16Y5 engine} .....................""'... 6-8
Inspection Using Special Tools
(D16Y8 engine) .........................'.'. 6-10
Valve Clearance
Adiustment ..."".....6-12
Valve Seals
Replacement (Cylinder head removal
not requiredl ................................ 6-1tl
Crankshaft Pulley and PulleY Bolt
Replacement ."...... &16
Timing Selt
lllustrated Index ............................... 6-17
Inspection .............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal ......,,......... 6-19
lnstallation ............. 6-20
Crankshaft Speed Fluctuation (CKF) Sensor
Repf acement .........6'22
Cylinder Head
lllustrated Index ............................... 6-23
Removal ................. 6-27
Warpage ................ 6-40
lnstallation ............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly ............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, D16Yg
enginesl "..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection .............. 6-36
Valves, Valve Springs and Valve Seals
Removal ........""..... 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement .........6-41
Reaming .......'......'.' 6-43
Valve Seats
Reconditioning .'....6'40
Valves
lnstallation ............. 6-tt3
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
lnstallation ............. 6-44

VTEC Rocker Arms
2.
Manual Inspection (D16Y5 engine)
3.
1.
4.
Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Move the intake secondary rocker arm on the No. 'l
cylinder manually.
Check that the intake secondary rocker arm moves
independently of the primary intake rocker arm,
SECoNDARY PtROCKER ARM. Push and pull.
Check the intake secondary
cylinder at TDC.
rocker arm of each
a lf the intake secondary rocker arm does not move,
remove the primary and secondary intake rocker
arms as an assembly and check that the pistons in
the secondary and primary rocker arms move
smoothly.
a lf any rocker arm needs replacing, replace the pri-
mary and secondary rocker arms as an assembly.
PRIMARY ROCKER ARM
4.
Manual Inspection (D16YB engine)
1.Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Reter to page 6-46 when installing the cylin-
der head cover.
Push the intake mid rocker arm on the No. 1 cylin-
der manually.
Check that the intake mid rocker arm moves indepen-
dently of the primary and secondary intake rocker
arms.
MID ROCKERARM
Check the intake mid rocker arm of each cylinder at
TDC,
lf the intake mid rocker arm does not move.
remove the mid, primary and secondary intake
rocker arms as an assembly and check that the pis-
tons in the mid and primary rocker arms move
smoothly.
lf any rocker arm needs replacing, replace the
primary, mid, and secondary rocker arms as an
assemory.
5,
6-7

5. With the specified air pressure appli€d, push up the
timing plate; the synchronizing piston will pop out
and engage the intake secondary rocker arm.
Visually check the engagement of the synchronizing
prston.
NOTE;
The synchronizing piston can be seen in the gap
between the secondary and primary rocker arms,
With the timing plate engaged in the groove on
the timing piston, the piston is locked in the
oushed out Dosition.
TIMIiIGPLATESPRIT{C
PRIMARY ROCKER ARM
AIR PRESSURE
GROOVE
SECO DARYROCKER ARM
TIMIT{G PLATE
TIMING SPRING
6-9
6. Stop applying air pressure and push up the timing
plate; the synchronizing piston will snap back to its
original position.
Visually check the disengagement of the synchro-
nizing pistons.
NOTE:
. When the timing plate is pushed up, it releases
the timing piston, letting the return spring move
the synchronizing piston to its original position.
7. Replace the intake rocker arms as an assembly if
either does not work correctly,
TIMING PLATE
oll PASSAGE --!
PRIMARY ROCKER
ARMSECOI{DARYROCKER ARM
TIMII{G SPRII{GRETURI{ SPRING
Remove the spscial tools.
After inspection, check that the malfunction indicator
lamp (MlLl does not come on.
TIMI G PISTOI{

4. Loosen the regulator valve on the valve inspection
tool and apply the specified air pressure.
Specified Air Pressure:
250 kPa {2.5 kgf/cm', 36 psil
PRIMARY ROCKERARM
SYNCHRONIZING SYNCHRONIZINGPISTON A PISTON B
Make sure that the intake primary and secondary
rocker arms are mechanically connected by the piston
and that the mid rocker arm does not move when
oushed manuallY.
5.
MID ROCKER SECONDARYARM ROCKER ARM
SECONDARYROCKER ARM
lf any intake mid rocker arm moves independently of
the primary and secondary rocker arms, replace the
rocker arms as a set.t
1.
8.
9.
Remove the special tools.
Use a 10 mm diameter rod to depress each lost
motion assembly through its full movement.
Replace any lost motion assembly that does move
smoothly.
After inspection, check that the MIL does not come
on.
ASSEMBLY
6-11

Valve Seals
Replacement (Cylinder head removal not requiredl
NOTE: Cylinder head removal is not required in thisprocedure.
The procedure shown below applies when using the in-
car valve spring compressor (Snap-on YA884S withY48845 - 2 A7/8" attachment).
!@@ Alway wear approved eye protection whenusing ihe in-cai valve spring compressor.
1. Turn the crankshaft so that the No. I and the No. 4pistons are at top dead center (TDC).
2. Remove the cylinder head cover and the rocker arm
assembly.
NOTE:
. Refer to page 6-30 for rocker arm assembly
removat.
. When removing or installing the rocker armassembly, do not remove the camshaft holder
bolts. The bolts will keep the holders, springs
and rocker arms on the shaft.
. Refer to page 6-46 when installing the cylinder
head cover.
Remove the fuel injectors and the wire harness.
Using the 8 mm bolts supplied with the tool. mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit over the cam-
shaft as shown.
lnsert the cross shaft through the top hole of thetwo uprights.
3.
4.
6-14
Intake Valve Seals:
6. Select the 7/8 in diameter short compressor attach-ment, and fasten the attachment to the No. 4 hole of
the leve. arm with the speed pin supplied.
8.
7.lnsert an air adapto. into the spark plug hole. pump
air into the cylinder to keep the valve closed whilecompressing springs and removing the valve keepers.
Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
neao.
OIL PASSAGES
Position the lever arm under the cross shaft so thelever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for thespring being compressed. Use the front position
slot on the lever as shown.
,
I
i'
OIL PASSAGES
IN-CAR SPRING COMPRESSOR
SLOT

Cylinder Head
lllustrated Index (cont'dl
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVE
VTEC SOLENOIDVALVE FILTEBReplace.
OIL CONTROLORIFICEClean.
INTAKE VALVE SEALReplace.VALVE SPRINGSEAT
INTAKE VAI.VEGUIOE
CAMSHAFTPULLEY
I
I
VALVE KEEPERS
SPRING RET
EXHAUST VALVESPRING
@
EXHAUST VALVESEALReplace.
8 x 1.25 mm37 N.m 13.8 kgt m,27 tbfitlApply engine oiltothe threads.
EXHAUSTVALVE
-vp
e,.io"o reassembring, crean at the parts in sorvent, dry them and appry rubricant to any contact parts.
D16Y8 engine:
LOST MOTIONASSEMgLY
ROCKER ARMASSEMBLYRemoval, page 6 30Inspection, page 6-34
5xl.0mm12 N.m {1.28.7 tbf.ft)
VALVE SPRINGSEATEXHAUSTVALVE O.RINGGUIDE Replace.Inspection, page 6 39Replacement, page 6 41Reaming, page 6 43
LOST MOTIONASSEMBLYHOLDER
INTAKE VALVEBemoval, page 6 38Installation, page 6 43
20 N.m 12.0 kgl.m, 14 tbf.ft)Apply engine oit to thethreads.
\
\
s9illl
CAMSHAFTInspection, page 6-36
OIL SEALBeplace.
CYLINDER HEADRemoval, page 6 27Warpage, page 6-40Valve seat reconditioning,page 6 40Installation, page 6-45
6x1.0mm12 N.m (1.2 kgt.m,8.7 lbf.ftlApply engine oil to thethreads,

Cylinder HeadRocker Arms
18.
19.
21.
22.
Removal (cont'd)
Remove the timing belt {see page 6-19).
Remove the camshaft pulley and back cover,
CAMSHAFTPULLEYClean when installing.
6x1.0mm8 x 1.25 mm37 N.m (3.8 kgf.m,21 tbtlrlApply engine oilto thebolt threads.
Remove the exhaust manifold {see pages 9-6 and 9_7).
Remove the intake manifold (see pages 9-2 thru 4).
Remove the cylinder head bolts, then remove thecylinder head.
CAUTION: To pr€vent warpage, unsclew lhe bohsin sequonce 1/3 turn at a time; rgpeat tho sequenceuntil all bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENGE:
6-30
Removal
1. Loosen the adjusting screws.
2. Unscrew the camshaft holder bolts, then,removethe rocker arm assembly.
NOTE:
a Unscrew the camshaft holder bolts two turns at at,me, in a crisscross pattern, to prevent damao_ing the valves or rocker arm assembly.. When removing the rocker arm assembly, do notremove the camshaft holder bolts. The bolts willkeep the camshaft holders, the springs and therocker arms on the shaft.
CAMSHAFT HOLDER BOLTS LOOSENINGSEOUENCE:
\(
ADJUSTING SCREWS

Disassembly/Reassembly
NOTE:
. ldentify parts as they are removed to ensure reinstallation in original locations'
. lnsDect rocker shafts and rocker arms (see page 6-35).
. Rocker arms must be installed in the same position if reused.
. when removing orinstallingthe rocker arm assembly,donot remove the camshaft holder bolts. The boltswill keepthe
holders, springs and rocker arms on the shaft.
-Zl prio, ,o reassemblinq, clean all the pans in solvent, dry them and apply lubricant to any contact points.
| - TNTAKE RocKER TNTAKE RocKER
D16Y7 engine:
Lefter "8" is stampedon rocker arm.
ARM A(4 placeslARM B
14 places)
INTAXE
ROCKER SHAFTSPRING{4 places)
ROCKER SHAFTCOLLAR14 plac.3l
ROCKER
I
II
I
BA\'A
fift L$\ft
:oo)[*o:
llll.I Jol----tNo.3 CAMSHAFT | | ruo. z cltusxerr 1i
T-* l=Bl-* d
,", 'l l=^ ^l
qJ?[l'-qJ'Ll
'I^ B A
EI
[ilHl"\9
t(cont'd)
6-31

Rocker Arms
Disassembly/Reassembly (cont'dl
NOTE:
. ldentify pans as they are removed to ensure reinstallation in original locations.. Inspect rocker shafts and rocker arms (see page 6-34).. Rocker arms must be installed in the same position if reused.t when removing or installing the rockerarm assembly, do not remove the camshaft holder bolts. The boltswill keeptheholders, springs and rocker arms on the shaft.
I erior to reassembring, crean a

the parts in sorvent, dry them and appry rubricant to any contact points.
D16Y5 engine:
ROCKER ARMS
TIMING PLATERUBBER BANO
(\
-]-
-P'g,rpt+.t't ll
\--,?|, -\2i lNo.5 CAMSHAFT _ lHOLDER l
No. 4 CAMSHAFTHOLDERNo. 3 CAMSHAFIHOLDERNo.2HOLDER
ra
I
EXHAUST ROCKERARM B{,1 plac€s)
EXHAUST ROCKEE SHAFT
Letter "A" is slamped
II{TAKE ROCKER SHAFT
!-r I
?h'ffi*ffi'
/^ ---IOCKER SHAFT
Letter "8" is stamped
6-32

Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, Dt6Y8 enginesl
NOTEr When reassembling the primary rocker arm,carefully apply air pressure to the oil passage of therocker arm.
1. Inspect the rocker arm piston. push it manually.- lf it does not move smoothly, replace the rockerarm assembty.
Dl6Y5 engine:
ROCKER ARM
TIMING PISTON
TIMING SPRING
SYNCHRONTZINGPISTON
SECONDARYROCKER ARM
MID ROCKER ARM
PRIMARY ROCKER
SYNCHRONIZINGPISTON A
NOTE:
. Apply oil to the pistons when reassembling.o Bundle the rocker arms with a rubber band to preventthem from separating.
6-34
(\
DI6YS engine:
NOTE: Set the timing plate and return spring as shownoerow.
RETURN
CAMSHAFT HOLDER
Dl6Yg engine:
2. Remove the lost motion assembly from the holderand inspect it. Test it by pushing the plunger withyour finger.- lf the lost motion assembly plunger does notmove smoothly, replace it.
LOST MOTION ASSEMBLY
\a
Pu3h
I