plastic HONDA CIVIC 1997 6.G Workshop Manual

Under-hood Emissions Control Label (1996, 1997 model)
Emission
Example:
Group ldentification
VACUUM HOSE ROUTING DIAGRAM
50ST {50 States):
THIS VEHICLE CONFORMS TO U.S, EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE TO 1996 AND
1997 MODEL YEAR NEW MOTOR VEHICLES.
/$ST (49 States/Federall:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO '1996 AND 1997 MODEL YEAR NEW
MOTOB VEHICLES,
CAL (Calitornis):
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE TO 1996 AND,1997 MODEL YEAR NEW PASSENGER CARS PROVIDED
THAT THIS VEHICLE IS ONLY INTROOUCED INTO COM-
MERCE FOR SALE IN THE STATE OF CALIFORNIA.
-VEHICLE Ei/ ISSION CONTROL INFORMATIONE\G\. rrMrr vtsNrs\JLK6\Dsp-A(.MFN 590(--,. O CIVIC fa:n!APOF!]V4 -AV.t' !-rirorrSrMAc \Y:/
CATALYST IwcN02S{2)sFr
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IDLESPEEOATDC
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TH SVEH CLE CONfOFMSTO U S. EPA AND STATEOF CALfORNIA RECULAI ONSAPPLICA8IElO 1997MOOET YEAR NEW MOTOR VEH CL'Silil]]lrl
Er!4#_"E!!ifl 4q!sq+HT-q4E!rL
N US€ TIEB l FULL
11211 .?2E AO2 HONDA MoTOR C0 , tTD
Engine and EvaPorative Families
Engine Family:V HN l.6VJGKGK
Model Year
T: 1996
V: 1997
T I
T|I
Manufacturer
HN: Honda
Displacem€nt
V: Light Duty Vehicle/Passenger Car
Fuel Systsm and Number of valves
J: Electronic Sequential Multiport Injection
(three or more valves per cylinder)
Fuel Type
G: Gasoline
Standard
F: 49 or 50 States Tier 1
K: 49 or 50 States Tier 1
1:California Tier 1
2: California TLEV
3: California LEV
4; California ULEV
Catalyst
E, F, G. H: Three Way Catalyst
OBD
K - T: OBD Equipped
Evaporative Family: v HN 1077 BYMAc'|T
Model Year
T:1996 |V:1997 lManufacturel
HN: Honda
Storage System
1:Canister
Canister Working Capacity (grams)
Canister Configulation
A: Plastic Housing (Closed Bottom)
B: Plastic Housing (oPen Bottom)
Fuel Systsm
Y: Fuel Injection
Fuel Tank
M: Metal
Standard
A: Current Evap
E: Enhanced Evap
Wild Card
1-37

81642 engine:
8 x 1.25 mm
22N,n 12 2 kdl'rn,
Replace.
,&16 rbt.ftl
Replace.
SELF.LOCKING8 x 1.25 mm16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
GASKETSReplace.
10 x 1 .25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
32.
PIPE A
RePlace'
Remove the damper forks (see section 18).
Disconnect the suspension lower arm ball joints
(see section 18).
Remove the driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may
com9 apart.
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
NoTE: Coat all precision-finished surfaces with
clean engine oil. Tie plastic bags over the driveshaft
enos.
34.
HO2S CONNECTOR
!^.
35.
36.
Lower the hoist.
Remove the upper and lower radiator hoses and
heater hoses,
37. Removs the ATF cooler hoses, then plug the ATF
cooler hoses and PiPes (A,/T)
UPPERRADIATOR HOSE
HOSES
(cont'd)

Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they areremoved so that each item can be reinstalled in its orioi-nal oosition.
'1. Using an appropriate-sized socket and plastic mal-let. lightly tap the valve retainer to loosen the valve
keepers before installing the valve spring compres-
sor.
Install the spring compressor. Compress the spring
and remove the valve keeper.
PLASTIC MALLET
SOCKET
VALVE SPRII{G COMPRESSORSnlp-on CF711 or KD-383whh #32 JAWS
6-38
L
(
3. Install the valve guide seal remover.
SEAL REMOVER vat vF GI nF !
4. Remove the valve seal.
I
VALVE GUIDE SEAL REMOVERLISLE P/N 57900 or KD3350

Valves
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
Installation (cont'd)
4. Install the valve spring and valve retainer. then
install the valve spring compressor. Compress the
spring and installthe valve keepers.
NOTE: Place the end of the valve spring with close-
ly wound coils toward the cylinder head.
lCornmercially available)Snap-on CFrll or KD - 3tX'with #32 JAWS
Lightly tap the end of each valve stem two or three
times with a plastic mallet to ensure proper seating
of the valve and valve keepers.
NOTE: Tap the valve stem only along its axis so you
do not bend the stem.
' 6-44
Installation
CAUTION:
. Make sure that all tockers are in alignment with their
valvgs when torquing the rocket assembly bolts,. Valve locknuls should be loosened and adiusting
screws backed off bofore installation.
. To prevont tho rocker arm a$smbly from coming
apad, l6av€ the camshaft holder bohs in the holdeB.
1. After wiping down the camshaft, camshaft seal andjournals in the cylinder head, lubricate both sur-
faces and install the camshaft.
2. Clean and install the oil control orifice with a new
O-ring.
CAMSHAFT SEALSeal housing surface should be dry.Apply a light coat of oil to camshaftand inner lip of seal.
3. Turn the camshaft until its keyway is facing up (No.
piston TDC).
OIL CONTROL ORIFICE

Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are
removed so that each item can be reinstalled in its origi-
nal Dosition.
l. Using an appropriate-sized socket and plastic mal-
let, lightly tap the valve retainer to loosen the valve
keeoers.
PLASTIC
Install the valve spring compressor. Compress the
spring and remove the vSlve keepers.
VALVE SPRINGCOMPRESSORATTACHMENT07757 - PJ1010A
VALVE SPRINGCOMPRESSOR ATTACHMENTEXTENSIONOTMAF - PRgOIOA
I
Sn.p-on CFr1lCOMPRESSOR
6-77
3. Installthe valve guide seal remover.
VALVE GUIDE SEAL REMOVERCOMMERCIALLY AVAILABLELtst-E P/N 571100 ()R KD3350
4. Remove the valve guide seal.
Valve Dimensions
lntake Valvo
A Standsrd {Newl; 32.90 - 33.10 mm (1.295 - 1.303 in}
B St ndard {New}: 101.00 - 101.30 mm (3.976 - 3'988 in}
C Stsndard (Nowl: 5./t5 - 5.,185 mm (0.2156 - 0.2159 in)
C Servico Limit 5.445 {0.21/l| in)
D Siandard (N!w): 1.05 - 1.35 mm (0.041 - O.05il inl
D S€.vice Limit: 0.85 mm {0.033 inl
Exhaust Valve
A Standard lNewli 27.90 - 28.10 mm (1.098 - 1.106 in)
B Stlndard {Nowl: 100.m - 1qr,90 mm {3.961 - 3.972 in)
C Stsndard {Now}: 5.450 - 5.,[60 mm {0.21,16 - 0.2150 in)
C Service Limit 5.420 10.213,0 inl
D Standard {New): 1.65 - 1.95 mm (0.065 - 0.077 in)
D Sorvico Limit: l.ils mm 10.057 inl

Fuel Supply System
Fuel Tube/Ouick-Connect Fittings (cont'd)
5. To prevent damage and keep out toreign matter,
cover the disconnected connector and oioe end
with plastic bags.
PI.ASIIC BAGS
11-228
Connection
!s@ Do not smoke while working on the fuel
system. Keep open llames away from your work area.
1. Check the pipe contact area for djrt and damage,
and clean if necessary,
Insert a new retainer into the connector if the retainer
is damaged, or after
. replacing the fuel pump.
. replacing the fuelfeed pipe.
. removing the retainer from the pipe.
N.w RETAINER(lnsert intothe connector.)
CONTACT AREA

Transmission Assembly
Removal (cont'dl
8. Remove the driveshafts (see section 161.
NOTE: Coat all the precision finished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends,
DRIVESHAFT
10 x 1.25 mrn43 N.m 14.4 kgt.m,32 rbf.frl
COTTER PINReplace. SELF12 x 1.25 mm49-59 N.m (5.0 -6.0 kgt.m,36-43 lbf.ft)
9. Remove exhaust pipe A.
Replace.12 x 1.25 mm64 N.m {6.5 kgt.m,47 lbf.tr)
GASKETSReplace.
IF\sELF-LocKtNG NUT.''1/Replace.8 x 1.25 mm16 N.m {1.6 kgf'm,12 tbf.ft)
EXHAUSTPIPE A
SELF-LOCKING NUTReplace.I x 1.25 mm22 N.m (2.2 kgf.m,16 tbt'fr)
SELF-LOCKING NUTReplace.D16Y5, D16Y7 engines:
33 N.m {3.4 kgf.m,25 lbt.ft)D16YB engine:10 x 1.25 mm54 N.m 15.5 kgl'm,40 lbf.ttl
SET RING
13-6
v'10. Remove the shift rod and extension rod.
SI'IIFT BOD
8x22mmSPRING PINReplace.
EXTENSION ROD
PIN PUNCH, 8.O mm(Commercially available)f-
'1'1. Remove the engine stiffeners and clutch cover.
D16Y5, D16Y8 engines:
10 x 1.25 mm44 N.m (4.5 kgt.m,33 tbf.tr)
I x 1.25 mm24 N.m (2.4 kgf.m17 lbt.frl
COVER
8 x 1.25 mm24 N.m 12.4 kgf'tn,17 tbt.tr)

70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s
Part NumberThickness
23931 - PL3 - 8000.60 mm 10.0236 in)
23932-PL3-8000.63 mm (0.0284 in)
c23933-PL3-8000.66 mm (0.0260 in)
D23334-PL3-8000.69 mm 10.0272 in)
E23935-PL3-8000.72 mm (0.0283 in)
F23936 - PL3 8000.75 mm (0.0295 in)
23937-PL3-B000.78 mm (0.0307 in)
23938-PL3-8000.81 mm (0.0319 inl
23939-PL3-8000.84 mm (0.0331 in)
23940-PL3-8000.87 mm {0.0343 in)
23941 - PL3 - 8000.90 mm (0.0354 in)
L23942-PL3-8000.93 mm (0.0366 in)
23943-PL3-8000.96 mm (0.0378 in)
N23944-PL3-8000.99 mm i0.0390 in)
o2394s-PL3-8001.02 mm (0.0102 in)
P23946-PL3-8001.05 mm {0.0413 in}
o23947-PL3-8001.08 mm (0.0{25 in)
23948 - PL3 800'1.1'1 mm (0.0437 4n)
23949-PL3-8001.14 mm (0.0449 inl
T23950-PL3-8001.17 mm (0.0461 in)
23951 - PL3 - 8001.20 mm (0.0472 in)
23952-PL3-8001.23 mm (0.0444 in)
239s3-PL3-8001.26 mm {0.0496 in)
X23954-PL3-8001.29 mm (0.0508 in)
2395s-PL3-8001.32 mm (0.0520 in)
z23956-PL3-8001.35 mm (0.0531 in)
23957-PL3-8001.38 mm (0.0543 in)
A823958-PL3-8001.41 mm (0.0555 in)
AC23959-PL3-8001.44 mm {0.0567 in)
AD23960-PL3-8001.47 mm (0.0579 in)
2396't-PL3-8001.50 mm (0.0591 in)
23962-PL3-8001.53 mm (0.0602 in)
AG23963-PL3-8001.56 mm (0.0614 in)
AH23964-PL3-8001.59 mm (0.0626 in)
23965-PL3-8001,62 mm (0.0638 in)
23966-PL3-8001.65 mm (0.0650 in)
AK23967-PL3-8001.68 mm (0.0661 in)
23968-PL3-8001.71 mm (0.0673 in)
23969-PL3-8001.74 mm (0.0685 in)
AN23970-PL3-8001.77 mm (0.0697 in)
AO23971- PL3 8001.80 mm (0.0709 inl
6. Installthe oil guide plate and selected thrust shim in
ths transmission housing
NOTE:
. Clean the thrust washer, spring washel and
thrust shim thoroughly belore installation.
. lnstall the thrust washer, spring washer and
thrust shim proPerlY.
THRUST SHIM
I
OIL GUIDEPLATE
TRANSMISSIONHOUSING
8.
o
10.
7, Install the thrust washer and spring washer in the
mainshaft.
lnstall the mainshaft in the clutch housing
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
Check the thrust clearance in the manner doscribsd
below.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Slide the mainshaft base and the collar over the
mainshaft.
CLUTCHHOUSING
11.
lz.
MAITISHAFT BASE07GAJ-PG20130COLLAF07GAJ -PG20120
{cont'd}
13-37
THRUST WASHER
SPRING WASI{ER

Mainshaft Thrust ShimI
I
Adjustment (cont'dl
b.Attach the mainshaft holder to the mainshaft asfollows:
NOTEI
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip istoward the transmission.
. Align the mainshaft holder's lip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSIIAFTHOLDER07GAJ-PG20110
d.
Seat the mainshaft fully by tapping on the end witha plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
u
e. Zero a dial gauge on the end ofthe mainshaft.
MAINSHAFT HOLDER07cAJ_PG20110
Turn the mainshaft holder bolt clockwise: stop turn,ing when the dial gange has reached its maximummovement. The reading on the dial gauge is theamount of mainshaft end olav.
CAUTION: Turning the mainshaft holder bolt morethan 60 degre€s after the needle ot the dial gauge
stops moving may damage the iransmission.
lf the reading is within the standard. the clearance iscorrecl.
lf the reading is not within the standard, recheck theshim thickness.
Standard: 0.11 - 0.18 mm {0.00it - 0.007 in}
t.
\,J

Transmission Assembly
Removal(cont'd)
14. Remove the driveshafts and the intermediate shaft(see section 16).
NOTE: Coat all precision the finished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends,
Remove the bolt, then disconnect the change elden-
sion.
Remove the clip and the spring pin, then disconnectthe change rod.
8x22mmSPRING PINCLIP Replace.
15.
13-50
17. Remove the front and the rear engine stiffensrs.
18. Remove the clutch cover.
CLUTCH COVER
6x1.0mm12 N.m (1.2 kg{.m,9 tbf.ftl
x 'l .25 mm
tJ
24 N.m {2.4 kgt m,17 rbt ftl