Intake HONDA CIVIC 1999 6.G User Guide

D16Y5 engine:
I x 1.25 mm20 N.m (2,0 kgf m, 14 lbf ft)
Apply engine oilto the
threads.ROCKEB ARMASSEMBLYFemoval, page 6-30
Inspection, Page 6-34
6x1.0mm12 N.m 11.2 kgf m, 8.7 lbf'ftl
Apply engine oilto the
threads.
VALVE KCEPERS
SPRING RETAINER
CAMSHAFTInspection, page 6-36
6x1.0mm12 N,m 11.28.7 tbf.ft)
WEC SOLENOIDVALVEBINTAKE VALVESPRING
INTAKE VALVE SEAL
Replace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
CAMSHAFTPUL|'IY
VTEC SOLENOIDVALVE FILTERReplace.
OIL CONTROLORIFICEClean.
VALVE
SPRING RETAINEB
EXHAUST V
SPRING
VE
EXHAUST VALVE
SEALt"o'""".uoau,
SEATReplace.
GUIDEInspection, page 6-39Replacement, Page 6-41
Reaming, page 6-43EXHAUSTVALVEOIL SEALReplace.
HEAD
8 x 1.25 mm
37 N.m 13.8 kgf.m,
27 tbf.frlApply engine oiltothe lhreads.
(cont'd)
6-25
INTAKE VALVERemoval, page 6 38
Installalion, Page 6 43Removal, page 6-27Warpage, Page 6 40
Valve seat reconditioning'page 6-40lnstallation, page 6_45

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,

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

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

D16Y8 engine:
No. 5 CAMSHAFTHOLDER
ARM B
ROCKER ARMS
No. 4 CAMSHAFTHOLOER
No. 3 CAMSHAFTHOLDER
No. 2 CAMSHAFTHOLDER
No. 'l CAMSHAFTHOLDER
R(rcKER SHAFTSPRING
Letter "B" is stampedLetter "A" is stamped
L
INTAKE SOCKER SHAFT
ROCKER SI{AFT
COLLARNUBBER BANDCOLLAR
EXHAUST ROCKER SHAFT
6-33

Rocker Arms and Shafts
Clearance Inspection
Measure both the intake rocker shaft and exhaust rocker
shaft.
1. Measure the diameter of the shaft at the first rocker
locatron.
2. Zero the gauge to the shaft diameter'
I
3. Measure the inside diameter of the rocker arm and
check for an out of-round condition.
Rockel Arm-to-Shaft Clearance
Standard (Newl:
lntake: 0.017 - 0.050 mm
{0.0007 - 0.0020 inl
Exhaust: 0.018 - 0.054 mm
(0 0007 - 0 0021 in)
Service Limit:0.08 mm {0.003 inl
Repeat these measurements on all the rockers.
- lf the clearance is over the service limit, replace the
rocker shaft and all over tolerance rocker arms.
6-35

6, Remove the camshaft holders. then measure the
widest ponion of the plastigage on each journal.
Camshaft-to-Holder Oil Clearance:
Standard lNew):0.050 - 0.08!t mm
{0.002 - 0.004 in}
Service Limit : 0.15 mm {0.006 in)
lf the camshaft-to-holder oil clearance is out ot tol-
erance:- And the camshaft has already been replaced,
you must replace the cylinder head.
- lf the camshaft has not been replaced, first check
the total runout with the camshaft supported on
V-blocks.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 inl max.
Service Limit: 0.04 mm {0.(X)2 in)
-7.
Rotate camshattwhile measuring.
L
- lf the total runout of the camshaft is within toler-
ance, replace the cylinder head.
- lf the total runout is out of tolerance, replace the
camshaft and recheck the camshaft-to-holder oil
clearance. lf the oil clearance is still out of toler-
ance. replace the cylinder head.
INTAKEEXHAUST
O16Y/ engine35.299 (1.3897)37.281 (1.4678)
D16Y5
engrne
PRI38.427 11.5129138.784 (1.5269)
SEC32.193 (1.2674)
D l6Y8
engrne
PRI36.77811.44791
38.008 (1.4964)MID38.274 (1.5068)
sEu37.065 (1.4592)
8. Check the cam lobe height wear.
Cam lobe height standard (New)
t/g a* rN Ex
- D16Y5 engine
PRI; Primary cam lobe, SEC: Secondary cam lobe
MtD: Mid cam lobe. T/B: Timing belt
lN: Intake, EX: Exhaust
PRIsEcMIDSEC
rts
- Dl6YE ongine
Unit mm (in)
Check this area {or wear.
6-37

Cylinder HeadValve Seats
Warpage
NOTE: lf the camshaft-to-holder oil clearances (see
page 6-36) are not within specification, the cylinder head
cannot be resurfaced.
lf the camshaft-to-holder oil clearances are within sDeci,
fications, check the cylinder head lor warpage.
lf warpage is less than 0.05 mm (0.002 in), cylin-
der head resurfacing is not required.
lf warpage is between 0.05 mm (0.002 in) and
0.2 mm {0.008 in), resurface the cylinder head.
Maximum resurface limit is 0,2 mm (0.008 in)
based on a height of 93 mm (3.66 in).
Measure along edges, and three ways across center.
Cylinder Head Height:
Standard {Newl: 92.95 - 93.05 mm
{3.659 - 3.66:} in)
6-40
\
Reconditioning
'1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf the guides are worn (see page 6-39).
replace them (see page 6-41) belore cutting the
valve seats.
VALVE SEATCUTTER(Commercially available)
2.
?
4.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutter
and the lower edge of the seat with the 60' cutter.
Check the width of the seat and adjust accordingly.
Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard (N€w):
Intake: 0.85 - 1.15 mm 10.033 - 0.045 in)
Exhaust: 1.25 - 1.55 mm {0.049 - 0.061 in}
Sorvice Limit:
Intake: 1.6 mm (0.063 inl
Exhausl: 2.0 mm (0.079 in)
Seat Width
5. After resurfacing the seat, inspect for even valve
seatingr Apply Prussian Blue compound to the
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against
the seat several times.

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