Temperature HONDA CIVIC 1997 6.G User Guide

Removal
Engine removal is not required for this procedure
!!!s@ Make sure iacks and salety stands are
f ta"eata"ea propetty and hoist brackets are attached to the
correct positions on the engine.
CAUTION:
. Use tender covels to avoid damaging painted sul-
faces.
o To avoid damage, unplug the wiling connectors
carefully while holding the connector portion to
avoid damage.
. To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F
{38"C} before loossning the tetaining bolts.
NOTE:
o Mark all wiring and hoses to avoid misconnectlon
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
. Inspect the timing belt before removing the cylinder
h ead.
. Turnthe crankshaft pu lley so that the No. lpistonisat
top dead center (see Page 6-21)
'1. Disconnect the negative terminal from the battery'
Drain the engine coolant (see page'10-7).
a Remove the radiator cap to speed draining.
Remove the intake air duct and air cleaner housing
(see page 5 3).
Remove the mounting bolt and lock bolt. then
remove the power steering (P/S) pump belt and
pump (see page 5'5).
Loosen the idler pulley center nut and adjusting
bolt' then remove the air conditioning (A'lc) com-
pressor belt (see Page 5-6).
Loosen the mounting nut and lock bolt. then
remove the alternator belt (see page 6-19).
Remove the P/S pump bracket (see page 5-12).
3.
4.
2.
6.
1.
8. Remove the throttle cable by loosening the locknut,
then slip the cable end out of the throttle linkage
NOTE:
. Take care not to bend the cable when removing it
Always replace any kinked cable with a new one
. Adjust the throttle cable when installing (see sec-
tion 1 1).
D16Y7 engine:
Dl6Y5, Dl6Y8 engines:
THFOTTLECABLE
(cont'd)
6-27
LOCKNUT
CABLE

13. Remove the upper radiator hose' heater hose and
water bYPass hose
WATEREYPASSHOSEUPPERRADIATORHOSE
14.
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
nector
a
a
a
ECT switch connector
ECT gauge sending unit connector
Throttle position sensor connector
Manitold absolute pressure (MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
Secondary heated oxygen sensor (secondary
HO2S) connector (D16Y7 engine)
Exhaust gas recirculation (EGR) valve lift sensor
connector (D16Y5 engine)
. VTEC solenoid valve connector (Dl6Y5, D16Y8
engrnes)
. VTEC pressure switch connector (D16Y5. D16Y8
engrnes,
. ldle air control (lAC) valve connector
15.Remove the spark plug caps and distributor from
the cylinder head.
Remove the uPPer bracket.
NOTE:
. Use a jack to support the engine before the
upper bracket is removed.
. Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25 mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPERBRACKET
'17. Remove the cylinder head cover'
CYLINDERHEAD COVER
(cont'd)
6-29

Valve Guides
7.
VALVESEAT
PFUSSIAN BTUE COMPOUNO
The actual valve seating surface. as shown by the
blue comDound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 60'cutter to
move it down, then one more cut with the 45'
cutter to restore seat width,
. lf it is too low (closer to the vslve edge), you
must make a second cut with the 30" cutter to
move it uD, then one more cut with the 45'cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45" cutter.
lnsert the intake and exhaust valves in the head and
measure the valve stem installed height.
Intake. Exhau3t Siem Installsd Height:
Standard (New): 53.17 - 53.6,4 mm
12.093 - 2.112 in)
Sorvice Limit: 53.89 mm (2.122 in)
lf the valve stem installed height is over the service
limit. reDlace the valve and recheck. lf its still over
the service limit, replace the cylinder head; the
valve seat in the head is too deep.
VALVE STEMINSTALLED HEIGHT
8.
\-
Replacement
1.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.
VALVE GUIDE DRIVERlCommerciallv available)5.3 mm
87 mm +- 57 mft
t3.43 in) | 12 24 inl
tr-r'10.8 mm(0.42 inl
or
VALVE GUIDE DRIVER, 5.5 mm
07742 - 0010100
Select the proper replacement guides. and chill them
in the freezer section of a refrigerator for about an
nour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150'C). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F (150"C1;
excessive heat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
{cont'd)
6-41

VTEC Control SYstem
The scan tool indicates Diagnostic Trouble Code {DTC) Pl259:
VTEC Solenoid Valve circuit
Refer to page 1'l-38 through 11 55 before troubleshooting
Troubleshooting Flowchart
YES
A problem in the WEC Pressure Switch circuit or
* Road Test:Accelerate in 1st gear to an engine speed over 6,000 rp '
Hold that engine speed for at leasttwo seconos'
lf the DTC P1259 is not repeated during the first road test'
repeat this test two more times
VTEC PRESSURE SWITCH 2P
CONNECTOR
Terminalside ofmale termtnals
WM
/1 IBLU/BLKI
/ 1 Y------rt--------- l I
\1-/ |I
I
I1
Wire side of femaleterminals
(cont'd)
6-51
The MIL has been teported on.
DTC P1259 is siored.
Check the VTEC Control SYsiem:
1. Do the engine control module(ECM ) Reset Procedure (see
section 11).
2. Start the engine
3. Warm uP the engine to normal
operating temPerature (cool
ing fan comes on).
4. Do the Road Test.*lntermittent failure, sYstem is OK
at this time.Check for Poor connectlons or
loose wires at VTEC Pressureswilch. VTEC aolenoid valvo and
ECM.
ls DTC P1259 indicated?
Test the VTEC Pressure Switch:
1. Turn the ignition switch OFF.
2. Disconnect the VTEC Pressure
switch 2P connector.
3. Check for continuity between
VTEC pressure switch 2P con
nector telminal No 1 and
No.2.
Reolace the VTEC Pre3sure switch.
Test the VTEC Pressure Switch
Wire:1. Turn the ignition switch ON (ll).
2. N4easure the voltage between
VTEC press u re switch 2P
connector No. 1 and bodyground,
Inspect lor an open or short toground in the wire between the
VTEC orassure swilch and ECM
{c101.lf the wire i3 OK, substitute a
known-good ECM and recheck.
{To page 6 52)

VTEC Control System
Troubleshooting Flowchart (cont,d)
VTEC PRESSURE SWITCH 2PCONNECTOR
Wire side of temaleterminals
OIL PRESSURE GAUGE(Comm.rcially avail.bte)
GAUGE JOINT ADAPTERSNAP.ON MT26.1710 x 1.0 ftm. Use new washer wheninstalling the sealing bott.
NOTE: Keep measuring time as shorr aspossible because engine is running witn noload lless than one minute).
6-52
(
VTEC SOLENOID VALVE lPCONNECTOF
Ir------r I
lLl.ll-r
II
It
Terminal side ofmale terminal
I
(From page 6-5l l
(To page 6-53)
Test tha VTEC P.es3uro SwitchWi.e:Measure voltage across the VTECpressure switch 2P connector.
Ropair opon in the wiro batwoenVIEC pr...urc switch and G lot .lf the wiro is OK, 3ubltitutr aknown-good ECM and rochack.
ls there battery voltage?
Test the VTEC Solenoid V.tve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No, I andbody ground.
ls there 14 - 30 O?
Te3t the VTEC Sotonoid Vatve:'1. Remove the VTEC pressureswitch and install the specialtool as shown. then reinstallthe VTEC pressure switch.2. Reconnect the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector,3. Connect the tachometer (seesection 1l).4. Start the engine.5. Warm up engine to normaloperatrng temperature (cool-ing fan comes on).6. Check oil pressure at enginespeed of 1,000,3,000 and5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,,7 psi)?Inipoct thg VTEC aolenoid valvel3ee P8go 6-54).
I

Timing Belt
Removal
NOTE:
. Replace the timing belt at 105,000 mites (168,000 km)according to the maintenance schedule (normal con-ditions/severe conditions).
lf the vehicle is regularly driven in one or more of thefollowing conditions, replace the timing belt at 60,OOOmiles (U.S.A.) 100,000 km {Canada).. In very high temperatures (over 110"F, 43"C).. In very low temperatures (under -20.F, 29.C).. Turn the crankshaft pulley so the No. 1 piston is attop dead center (TDC) before removing the belt (seepage 6-57).
. Inspect the water pump before installing the timingbelt {see page 10-14).
1.
IOLER PULLEY BRACKETEOLT10 x 1.25 mm44 N.m 14.5 kgf.m, 33 bnft)
6-62
Remove the splash shield (see page 5-9).
Remove the adjusting bolt and mounting bolts, thenremove the power steering (P/S) pump belt andpump.
8xL25mm24 N m {2.{ kgf.m, 17 lbf.ft)
Loosen the idler pulley bracket bolt and adjusting bolt,then remove the air conditioning (A,/C) compressorbelt aDJUsnNG
44 N.m 14.5 kgt.m, 33 lbf.ft)
P/S PUMP LOWER ARACKET
a\
4. Loosen the mounting nut and lock bolt, then removethe alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgt.m.17 rb{.ftl
5. Remove the upper bracket (see page 6-69).
NOTE:
. Use a jack to support the engine before removingthe upper bracket.
o Place a cushion between the oil pan and the jack.
Remove the P/S pump lower bracket
8 x 1.25 mm24 N.m 12.,1 kgf.m,17 tbf.ftl
l0 x 1.25 mm
'-f'
MOUNTING10 x 1.25 mm44 N.m (4.5 kgf.m.33 rbf.fttBELT
HEAT SHIELD

Removal
Engine removal is not required for this procedure.
!@@ Make sure jacks and safety stands are placed
properly and hoist brackels are attached to correst posi-
tion on the engine,
CAUTION:
o Use fender covers to avoid damaging painted sur-
faces.
To avoid damage, unplug the wiling connectors
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F {38'Cl
before loosening the retaining bolt.
NOTE:
. Unspecified items are common.
. Mark all wiring and hoses to avoid misconnection.
AIso, be sure that they do not contact other wiring or
hoses or interfere with other parts.
o Inspect the timing belt before removing the cylinder
n eao.
. Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (see page 6-64).
1. Disconnect the negative terminal from the battery.
Drain the engine coolant {see page 10-7).
. Remove the radiator cap to speed draining.
Remove the strut brace (see page 5-2).
Remove the intake air duct and air cleaner housing
(see page 5-3).
Remove the adjusting bolt and mounting bolt, then
remove the power steering (P/S) pump belt and pump
(see page 5 5).
2.
3.
4.
\
ADJUSTING
6. Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (A/C) com-
pressor belt.
IDLER PULLEY BRACKETBOLT10 x 1.25 mm44 N.m {4.5 kg,l.m, 33 lbt.ft}
7. Loosen the mounting nut and lock bolt, then remove
the alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgf.m,17 tbtftl
ALTERNATORBELT10 x 1.25 mm,l,l N.m {4.5 kgf.m,33 tbf.ft,
(cont'd)
6-67

WATER BYPASS
HOSE
14. Remove the upper radiator hose, heater hose and
water bvpass hose.
HEATER
Remove the engine wire harness connectors and wlre
harness clamps from the cylinder head and the intake
manifold.
Four fuel injector connector
Engine coolant temperature (ECT) sensor connec-
tor
ECT gauge sending unit connector
ECT switch connector
ldle air control (lAC) valve connector
Manifold absolute pressure (MAP) sensor connec-
tor
Throttle position sensor connector
Primary Heated oxygen sensor (Primary HO2S)
connecror
VTEC solenoid valve connector
15.
a
a
a
a
a
\
16.
17.
Remove the spark plug caps and distributor form
the cylinder head.
Remove the upper bracket.
NOTE:
. Use a jack to support the engine before removing
the upp€r bracket is removed.
. Place a cushion between the oil panandthejack.
12 x 1.25 fin74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cylinder head cover.
{cont'd)
6-69

t
Valve Guides
Replacement
1. As illustrated below, use a commerciallv available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. ln most
cases, the same procedure can be done using the
sDecial tool and a conventional hammer.
COMMERCIALLY AVAILABLEVALVE GUIDE DRIVER
87 mm -L- sz mm(3.43 inl I tz.zr int
rE-tt
10.8 mm10.42 inl
olVALVE GUIOE DRIVER,5.5 mm077,P - 0010100
Select the proper replacement guides and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150"C). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warp tho head.. Do not get tho head hotter than 300"F {150"C};excesgive heat may loosen thg valve seats.. To avoid burns. use haaw gloves whon handling
the heatod cylinder head.
6-80
Working from the camshaft side, use the driver and
an air hammer to drive the guide about 2 mm (0.1 in)
towards the combustion chamber. This will knock off
some ofthe carbon and make removaleasier.
CAUTION:
. Always wsar safety goggles or a face shield whsn
driving valve guides.
. Hold the air hammer dir€ctly in line with the
valve guide to prevont damaging thg dtiver.
Turn the head over and drive the guide out toward
the camshaft side of the head.
VALVE GUIOE DRIVER,5.5 mm077{2 - 0010100
lf a valve guide still won't move. drill it out with a8.0 mm (5/16 in) bit, then try again.
CAUTION: Drill guides only in extreme cases; you
could damago the cylinder head if ths guide br6aks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
-:^-,65i^q
NNSp-<

Crankshaft
Installation (cont'd)
7. Installthe main bearing caps.
Check clearance with plastigage (see page 7-9), thentighten the bearing cap bolts in 2 steps.
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft)
Second stop:
B1642 engine:
76 N.m {7.8 kgf.m, 56 lbf.ft)
D16Y5, D16Y7, D16Y8 engines:
51 N.m (5.2 kgf.m, 38 lbf.ft)
NOTE: Coat the thrust washer surfaces and boltthreads with oil.
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
oocoo
CAUTION: Whenever any crankshaft or connectingrod bearing is replaced, it is necGssary after reassom-bly to run the engine at idling spe6d until it reachesnormal operating temperature, than continue to runit for approximately 15 minutos.
:V fr\-/.---\-/.-
7-24
NOTE:
. Use liquid gasket, part No. 08718 - 0001 or08718-0003.
. Check that the mating surfaces are clean and drybefore apptying liquid gasket.
. Apply liquid gasket evenly, being careful to coverall the mating surface.. To prevent oil leakage, apply liquid gasket to theinner threads of the bolt holes.. Do not install the parts if five minutes or morehave elapsed since applying the liquid gasket.
Instead reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
L Apply liquid gasket to the block mating surface ofthe right side cover, then install it on the cylinderblock.
Bl6A2 engine;
Apply tiquid gaslet alongthe broken line.
D16Y5, D16Y7, D16Y8 engines:
RIGHT SIDE COVER