tension HONDA CIVIC 1996 6.G Workshop Manual

Unit of length: mm lin)
STANDARD {NEW) SERVICE LIMITMEASUREMENT
Differential
Dtri"*"t"|p'.b"gear
S"t rrg-t" b""il"s
Pinion shaft contact area LD.
Carrier-to pinion clearanceDrive shaft contact area l.D.Carrier to driveshaft clearance
BacklashLD.Pinion gear to-pinion shafl clearance
)uter race clearance
18.010 18.028'0.7091 - 0.7098)
0.023 0.057 (0.0009 - 0.0022) 0.1 (0 004)
26.025 - 26.045 (.0246 1 0254\0.045 0.086 (0.0018 - 0.0034) 0.12(0.005)
0 05 - 0.15 i0 002 0.006)18 042 18.066 {0.7103 0.7" l3)
0.055 - 0.095 (0.0022 - 0.0037) 0.15 {0.006)
0 0.15 (0 - 0.006) Adjlrst
MEASUBEMENT Wire DiaO.D. Free Length I No. of Coils
SpringsPH regulator valve spring 1 2 (0 047)
PH control valve spring 1 7 {0.067)PL regulator valve spring 0 9 (0.035)
PH'PL control valve spring 1 0 (0 039)
crutlh reduc'ns vdrve spnns ] :19 9]:lLLbrication valve spring I b (u ubJr
Shitt valve spring 1 4 (0.055)
Shift control valve spring 1 0 (0.039)
Stan clutch control valve spring 0.4 (0 016)
Pitot regulator valve spring 0.6 (0 024)
Start clutch valve accumulator spring 1 2 \0 O47)
Reverse control valve spring 1 2 (0.047)
Shift inhibitor valve spring 1 3 (0 051)
9.0 {0.354)13.4 (0.528)
1.2lO.2A3\10.0 (0.394)
16.8 (0.661)
13.4 (0.528)
8.2 (0.323)
1 .4 t0.29114.1 (0.161)
5.7 t0.224)8.3 {0.327)9.4 (0.370)
13.2 (0.520)
26.7 (1.051)
39.4 (1.551)
14.6 (0.575)
31.4 (1.236)
44.4 \1.14al51.6 (2.031)
34.1 (1.343)
19.3 (0.760)
12.1 (0.476)
9.5 (0.374)
29.8 (1.173)
31.4 (1.236)
48.3 (1.902)
r0.08.11.28.68.0
13.01.56.85.012.311.010.6
Section 14
SteeringSection 17
M/S: [,4anual steering, P/Sl Power steering*: When using a ne; bett, adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
Readjust the deflection or tension to used belt values.
cw
MEASUREMENTSTANDARD {NEWI
Steering wheelPlay at steering wheel circumferenceStarting load at steering wheelcircumferenceN (ksf, lbf)Manual steeringPower steering Engine running
0 - 10 (0 0.4)
15 (1.5,3.3)
29 (3.0,6.6)
GearboxAngle of rack guide screw loosened M/S
from locked position P/S
Preload at pinion gear shaft N m (kglcm, lbfin) M/S
20!5"20'Max0.5 - 1.7 (5 - 17,4.3 - 14.8i
0.6 1.2 (6 - 12, 5.20 - 10.42)
Pump pressure with valve closed(oil temp./speed: 40'C (105"F) min./idleDo not run for more than 5 seconds).kPa (kgtcm?, psi)
6,400 - 7,400 {65 - 75, 920 - 1,070)
Power steeringfluidRecommended power steering fluid
Fluid capacity | {US qt, lmp q0Reservoir
HONDA Power Steering Fluid
0.85 (0.90,0.75) at disassembly0.4 {0.42.0.35}
7.5 11.0 {0.30 - 0.43)with used belt
5.0 7.0 (0.20 0.28) with new belt10.5 - 14.0 10.41 - 0.55) with used belt7.5 10.010.30 0.39) with new belt
390 540 {40 55,88 '120) wrth used bek
340 - 490 (35 - 50, 77 - 110) with used belt
740 880 (75 - 90, 170 - 200) with new belt
640 780 (65 - 80, 143-176)with newbelt
Power steeringbelt*
Deflection with 98 N (10 kgf,22 lbf)
between pulleys '99 modell 81642 Engine Type only
'96 '99 models: Other Engine TYPes
ron.ionffiN (kgf, lbf) '99 model: 81642 Engine Tvpe only'96 -'99 models: Other Engine TYPes'99 modelr 81642 Engine TYPe onlY'96 '99 models: Other Engine TYPes
3-17

MEASUREMENTSTANOARO INEW}SERVICE LIMIT
algnmenlCamber FrontRearCaster FrontTotaltoe FrontBearFront wheel turning angle Inward wheelOutward wheel
0"00'1 1"-1.1 1'1'40' I 1"In'1.01 2.0 {1/16 t 1/'16)In 2.0 ljB (1/161 1/16)39.50'33'10'(Reference)
Bim runout Aluminum wheel AxialBadialSteelwheel AxialRadla I
0 0.7 (0 - 0.03)0- 0.7 (0 - 0.03)0 - 1.0 (0 0.04)0 - 1.0 (0 0.04)
2.0 (0.08)
1.5 10.06)2.0 {0.0B)1.5 (0.06)Wheel bearingEnd play FrontRear0 0.0s (0 - 0.002)0 0.05 (0 0.002)
Standards and Service Limits
Suspension - Section 18
Brakes - Section 19
*1. 5410 Stamped on the caliper body.*2. 2056 Stamped on the caliper body.
Air Conditioning - Section 22
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it of{.Readjust deflection or tension to used belt values.
3-18
MEASUREMENTSTANDARO INEWISERVICE LIMIT
Parklng brakePlay in stroke at 196 N (20 kgf, 44 lbfi lever forceTo be locked when pulled6 - I notchesFoot brakepeoalPedal height (with floor mat removed) M/TA/'T, CVTFree play
156.5 {6.16)161 (6 5/16)1 5(1/16-3/16)
Master cvlinderPiston to pushrod clearance0 - 0.4 (0 0.02)
Disc brakeDisc thickness FrontRearDisc runout FrontRearDisc parallelism Front and rearPad thackness Front
Rear
20.9 - 21.8 (0.82 - 0.86)8.9 - 9.1 (0.350 - 0.358)
9.5 10.5*'8.5 - 9.5*'7.0 8.0 (0.28-0.3r)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)
1.6 (0.06)1.6 (0.06)'r.6 (0.06)
Rear brakedrumLD.Lining thickness200 17.a7l4.0 (0.16)201 \7 .9112.0 {0.08}
MEASUREMENTSTANDARD INEWI
Conditioning
SANDEN
Lubricant type: SP 10 (P/N 38897 - Pl3 - A01AH or 3889Lubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
I - P13 A0li lFor refrigerant: HFC-134a (R,134a))
| 20 \2t3 0.11
I 45 (1 2/3, 1.6)10 (1/3,0.4)
10 t1/3,0.4)NIPPONDENSOLubricant type: ND'O|L8 (P/N 38899 - PR7 - 003) (For ReLubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
f.igerant: HFC,134a (R-134a))25 (s/6 0.9)60 (2,2.11
10 (1/3,0.4)
10 (1/3.0.4)
CompressorSANDENLubricant type: SP-10Lubricant capacity ml lfl oz, lmp oz)Field coil resistance at 68'F (20"C) OPulley-to-pressure plate clearance
130 150 (4 1/3 4.6, 5.0 - 5.3)
0.5 r 0.15 10.020 t 0.006)
NIPPONDENSOLubricant type: ND-OlL8 {P/N 38899 - PR7 ,003 or P/N 38899 pR7 - AO1) (For Refrigerant: HFC 134a {R,134a))Lubricant capacity m{(fl oz, lrnpoz) | 14O(4.7,4.9J -15S{5.2.5.4)Stator coil resistance at 20'C (68.F) 0Pulley-to-pressure plate clearance3.4 - 3.80.510.15 (0.0210.006)
Compressorbelt*Deffection with 98 N (1Okgl.22lbllbetween pulleys7.5 - 9.5 (0.30 0.37) with used belt5.0 - 6.5 (0.20 - 0.26)with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge340 490 i35 50, 77 - 110) with used bell690 - 830 (70 - 85, 150 190) with new belt

ElectricalSection 23
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off
Readiust deflection or tension to used belt values
Unit of englh: mm {n)
MEASUREMENTSTANDARD {NEW}
lgnition coilRated voltage VPrimary winding resistance at 68'F (20'C) oHITACHITEC
Secondary winding resastance at 68'F 120"C) kOHITACHITEC
12
0.45 0.550.63 0.11
22.4 - 33.612.A - 19.2
lgnition wireResistance at 68'F (20'C) kf)
Firing order
25 max.1-3-4 2
Spark plugTypeGap
See section 231.1 3, (o.o€ -3*.)
lgnition timingAt idle' BTDC lRed)
Alternator belt+Deflection with 98 N (10 kgf,22lbf)between pulleys8.0 - 10.5 {0.31 - 0.41} with used belt
6.0 - 8.5 {0.26- 0.33)with new belt
Belt tension N (kgf, lbf)
Measured with belt tension gauge340 - 490 (35 - 50, 77 110) with used belt
540 - 740 (55 - 75, 121. 165)whh newbert
(MITSUBISHI)Output l3.5 V at hot ACoal resistance (rotor) at 68'F (20"C) kO
Slip rins O.D.Brush lengthBrush spring tension g (oz)
STANDARD INEWI SERVICE LIMIT
753.4-3.8 I -
Z2.j \0.A9) 22.2 \0.47)19.0 (0.75) 5.0 (0.20)
340 420 (12.0 14.8)
Alternator(DENSOiOutput '13.5 V at hot A
Coil resistance (rotor) at 68'F (20'C) k0
Slip ring O.D.Erush lengthBrush spring tension g (oz)
802.2 - 3.014.4 (0.57) | 14.0 (0.55)
10.5 (0.41) 1.5 (0.06)
330 {11.6)
Starter(MITSUEA
1.0 kw1.2 kW)
TvpeCommutator mica depthCommutator runoutCommutator O.D.Brush lengthBrush spring tension (new)
N (ksf, lbf)
Gear reduction0.4 - 0.5 (0.016 - 0.020) 0.15(0.006)
o o.o2 (o - 0.000e) | o.o5 (o.oo2)
28.0-28.1 (1.102 1.106) | 27.5(1.083)
15.8 - 16.2 10.62 - 0.64) 11.0 (0.43)
15.7 - 11 .1
{1.60 - 1.80, 3.5 - 4.0i
3-19

20. Remove the shift cable (CVT)
WASHER
Pt-Aslc
21. Disconnect the Power
switch connector, and
cramp.
LOCKNUT29 N.m {3.0 kgf m,22lbf'ft}
steering pressure (PSP)
remove the wire harness
CLIP
ll
I
Remove the radiator caP.
!!!@ usa care when l€moving the tadiator
Ap to avoid scalding by hot coolant or steam'
Raise the hoist to full height.
SHIFT CABLE
(cont'd)
25.
26.
27.
24. Remove the front tires/wheels and splash shield.
u x l.u mm SHIELD9.8Nm(1 0 kqt'm,
7.2lbf.ftl
Drain the engine coolant (see page 10-7). Loosen
the drain plug in the radiator.
Drain the transmission fluid Reinstall thedrainplug
using a new washer (see section 13, 14).
Drain the engine oil. Reinstall the drain bolt using a
new washer (see page 8-6).
28. Remove the shift rod and extension rod (M/T)
SHIFT ROD
EXTENSIONROD
8 x 1.25 mm22 N.m t2.2 kgf'm, 't6lbtft)
ER
6x1.0mm

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

Timing Belt
Inspection
1.
2.
3.
Remove the cylinder head cover.
. Refer to page 6 46 when installing.
Remove the upper cover (see page 6 19).
Inspect the timing belt for cracks and oil or coolantsoakrng.
NOTE:
. Replace the belt if oil or coolant soaKeo.. Remove any oil or solvent that gets on the belt.
Rotate pulleyand inspect belt.
After inspecting, retorque the crankshaft pullev bolt{see page 6- 16).
o- I6
Tension Adjustment
CAUTION: lt*ays aa;j"t the timing bett rension withthe engine cold.
NOTE:
. The tensioner is spring loaded to apply tension to thebelt automatically after making the following adjustment.
. Always rotate the crankshaft counterclockwise whenviewed from the pulley side. Rotating it clockwisemay result in improper adjustment of the belt ten-sion.
. lnspect the timing belt before adjusting the belt ten-ston.
1.Remove the cylinder head cover.
. Refer to page 6,46 when installing.
Remove the upper cover (see page 6,'19).
Rotate the crankshaft five or six revolutions to setthe belt.
Set the No. 'l piston at TDC (see page 6-21).
Loosen the adjusting bolt 180'.
2.
3.
4.
5.
\I
ADJUSTING BOLT44 N.m {4.5 kgt m,33 rbf.ft)
7.
8.
Rotate the crankshaft counterclockwise three teethon the camshaft pulley.
Tighten the adjusting bolt.
After inspecting, retorque the crankshaft pulley bolt(see page 6-16).

Timing Belt
Removal (cont'd)
9. Remove the CKF sensor from the oI pump.
10. Loosen the adjusting bott lgO..to remove tension from theretighten the adjusting bolt.
12 N.m 11.2 kgt.m,8.7 rbf.ftl
Push the tensioner
timing be lt. then
AD.'USNNG BOLT4{ N.m 14.5 kgt m,33 tbtftl
1 1. Remove the timing belt.
6-20
lnstallation
Install the timing belt in the reverse order of removal;Only key points are described here.
l. set rhe timing belt drive pulley so that the No. 1 pis-ton as at top dead center (TDC), Align the groove onthe timing belt drive pulley to the pointer on the oilpump.
TDC MARKPOINTER
I
t
I
TIMING BELTDBIVE PULLEYClean.I
2. Set the camshaft pulley to TDC. Align the TDCmarks on the camshaft pulley to the cylinder headsurface.

3. Install the timing belt tightly in the sequence shown'
OTiming belt drive pullev (crankshaft) )@Adjusting
pulley -towater pump pulley J@Camshatt pulley'
NOTE: Make sure the timing belt drive pulley and
camshaft PulleY are at TDC
7.
Loosen and retighten the adiusting bolt to tension
the timing belt.
lnstall the lower cover and upper cover.
NOTE: Clean the upper and lower covers before
installation.
lnstall the crankshaft pulley, then tighten the pulley
bolt (see page &16)
Rotate the crankshaft pulley about five or six turns
counterclockwise so that the timing belt positions
on the Pulleys.
Adjust the timing belt tension (see page 6-18).8.
L
9. Check that the crankshaft pulley and camshaft pul-
ley are both at TDC.
CRANKSHAFT PULLEY:
CAMSHAFT PULLEY:
lf the camshaft and crankshaft pulleys are not posi-
tioned at TDC, remove the timing belt and adjust
the position following the procedure on page 6-20'
Then reinstall the timing belt.
After installation, adjust the tension of each belt
. See section 23 for alternator belt tension adjust-
ment.
a See section 22 tot NC compressor belt tension
adjustment.
. See section 17 for P/S pump belt tension adjust
ment,
(wHrTE)
"UP" MARK
TDC MARK
11.
6-21

Special Tools
(\
Ref. No. I Tool NumberDescriptionOty Page Relerence
q oTHAH PJ7010B
g I 07JAA-001020A
g I 07JAB-0010204
I 07JAB - 0010404
g 07LAJ - PR3020A
|6) 07MAA - PR70100
g I ozvu,r - enu orzo
g 07MAF - PR9010A
g 07742 - 0010100(!D I 07757-PJ10104
Valve Guide Reamer,5.5 mm
Socket, 19 mm
Holder Handle
Pulley Holder Attachment. 50 mm
Air Stopper
Tappet Adjuster
Tappet Locknut Wrench
Valve Spring Compressor Attachment ExtensionValve Guide Driver, 5.5 mm
Valve Spring Compressor Attachment
1 I 6-81
1 659
1 6-59
1 ] 6-5s
1 I 6-55
1 6-57
1 6-57
1 J 6-77
1 6-80, 81
1 6-71
ta;
aL)'n
-=<-,,LE;;
(D
a
6-50
\-

Inspection
Remove the cylinder head cover.
NOTE: Refer to page 6-86 when installing the cylin-
der head cover.
Inspect the timing belt for cracks and oil or coolant
soakrng.
NOTE:
. Replace the belt if oil or coola nt soaked.
. Remove any oil or solvent that gets on the belt'
I
Rotate PUlleYand inspect belt-
After inspecting, retorque the crankshaft pul
to 177 N.m (18.0 kgf'm, 130 lbf'ft)
'L
lnspect thrs area
Tension Adiustment
CAUTION: Always adiust timing belt tension with the
engine cold.
NOTE:
. The tensioner is spring-loaded to apply proper ten
sion to the belt automatically after making the follow-
ing adjustment.
. Always rotate the crankshaft counterclockwise when
viewed from the pulley side. Rotating it clockw'se
may result in improper adjustment of the belt ten-
sion.
1, Remove the cylinder head cover.
NOTE; Refer to page 6-86 when installing the cylin-
der head cover.
2. Set the No. 1 piston at TDC (see page 6-64)
3. Rotate the crankshaft live or six revolutions to set
the belt.
4. Set the No. 1 Piston at TDC
ADJUSTING BOLT
54 N.m(5.5 kgt.m, a0 lbtftl
5.
7.
8.
Loosen the adjusting bolt 180'.
Rotate the crankshaft counterclockwise three teeth
on the camshaft PulleY.
Tighten the adjusting bolt.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf'm, 130 lbnft)
ley bolt
6-61