oil type HONDA CIVIC 1996 6.G User Guide

Crankshaft
Inspection
. Clean the crankshaft oil passages with pipe cleaners
or a suitable brush.
. Check the keyway and threads.
Alignment
. Measure runout on all main journals to make
sure the crank is not bent.
. The difference between measurements on eachjournal must not be more than the service limit.
Crankshaft Total Indicated Runout:
Bl6A2 engine:
Standard (Newl: 0.020 mm {0.0008 in} max.
Service Limit: 0.030 mm {0.0012 inl
D16Y5, D15Y7, D15Y8 engines:
Standsrd {New): 0.03 mm (0.001 in} max.
Service Limit; 0.0i1 mm 10.002 in)
Support with lathetype tool or V blocks.
7-14
Out-of-Round and Tapet
. Measure out-of-round at the middle of each rod
and main journal in two places.
a The difference between measurements on eachjournal must not be more than the service limit.
Joulnal Out-of-Round:
81642 engine:
Standard (New): 0.0004 mm {0.0002 in) max.
Service Limit: 0.006 mm {0.0002 in)
Dr6Y5, Dl6Y7, D16Y8 engines:
Standard (Newl: 0.0025 mm (0.0001 inl max.
Service Limh: 0.005 mm (0.0002 inl
round at middle.
. Measure taper at the edges of each rod and mainjournal.
. The difference between measurements on eachjournal must not be more than the service limit.
JournalTaDer:
B16A2 ongine:
Standard lNewl: 0.005 mm (0.0002 inl max.
Service Limit: 0.010 mm (0.00i1 inl
D16Y5, D16Y7, Dl6YB engines:
Standard (New): 0.0025 mm {0.0001 in) max.
Service Limit: 0.005 mm (0.0002 in)
\

T
6. Measure the clearance between the spacer collar
and sth gear.
Standard: 0.06 - 0.19 mm 10.002 - 0.007 inl
Service Limit: 0.31 mm (0.012 inl
4TH GEAR
DIALINDICATOR
I
-<=q,
7.
5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer coilar
Standard: 23.53 - 23.56 mm
10.926 - 0.928 in)
Sowice Limit 23.51 mm {0.926 in}
SPACERCOLLAR
sTH GEARSIDE
lf distance @ is less than the service limit, replace
the spacer collar with a new one,
lf distance @ is within the service limit, measure
thickness of 5th gear.
Siandatd:28.1:2 - 28.17 mm
11.119 - 1.121 in)
Servica Limit: 28.35 mm (1.116 inl
sTH GEAR
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth Oear with a new one.
lf the thickness of sth gear is within the service
limit, replace the 5th synchro hub with a new
one.
Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEARING PULLER(Commercially
availablel
CAUTION: Remov€ ths synchro hubs using a press
and steel blocks as shown. Us€ of a iaw-type pullel
can caus€ damage lo the gear teeih.
Support 4th gear on steel blocks. and press the
mainshaft out of the sth svnchro hub as shown.
{cont'd)
13-17

Driveshafts
Removal (cont'd)
8. Remove the cotter pin from the lawer arm ball joint
castle nut. and remove the nut.
Install a 12 mm hex nut on the ball joint. Be sure
that the hex nut is flush with the ball joint pin end,
or the threaded section of the ball joint pin might be
damaged by the special tool.
Use the special tool as shown in section 18, to sepa-
rate the ball joint and lower arm. Be careful not to
damage the ball joint boot.
NOTE: lf necessary, apply penetrating type lubri,
cant to loosen the ball joint.
Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaft endpast the groove.
10.
11.
3.5 mm
07MAC - SL00200
SCREWDRIVER
16-4
12. Pull the inboard joint, and remove the driveshaft
from the differential case as an assembly. Do notpull on the driveshaft; the inboard joint may come
apart. Use care when prying out the assembly, andpull it straight to avoid damaging the differential oil
seat.
13. Pull the knuckle outward, and remove the driveshaft
outboard joint from the front wheel hub using aplastic hammer.
SCREWDRIVER
DRIVESHAFT

I
14.
Apply power steering fluid to the surface of the spe-
cial tool. Set the new seal rings over the special tool
from the smaller diameter end of the tool, and
expand the seal rings. Do two rings at a time from
each end of the sleeve.
NOTE;
. Do not over-expand the seal ring. Installthe resin
seal rings with care so as not to damage them'
After installation, be sure to contract the seal
rings using the specialtool (sizing tool).
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleeve seal rings as they are not compatible
Set the special tool in the grooves in the sleeve, and
set each ring in each groove securely.
NOTE: After installation, compress the seal rings
with your fingers temPorarilY
BALL JOINT BOOI CLIP GUIDE
07S7,1- SA50800
SLEEVE
15. Apply power steering fluid to the seal rings on the
sleeve, and to the entire inside surface of the spe-
cial tool.
16. lnsert the sleeve into the specialtool slowly'
17. Move the sleeve each direction several times to
make the seal rings snugly fit in the sleeve'
NOTE: Be surerings are not turned uP.
SITEVE SEAL RINGSIZING TOOL0797a - SA5020A or07974 - SA50200
that the seal
fr
J
17-57
18. Apply power steering fluid to the surface o{ the pin-
ion shaft. Assemble the sleeve over the pinion shaft
by aligning the locating pin on the inside of the
sleeve with the cutout in the shaft. Then install the
new circlip securely in the pinion shaft groove'
NOTE:
Be careful not to damage the valve seal ring
when inserting the sleeve.
Installthe circlip with its radiused side toward the
sleeve.
Apply power steering fluid to the seal ring lip of the
valve oil seal. then install the seal in the valve hous-
ing using a hydraulic press and special tools as
shown.
CAUTION: Install the valve oil seal with its grooved
side facing the tool.
'19.
ATTACHMENT.32x35mm0774.6 - q)101(x)Pre3s
IDRIVER07749 - 0010000
VALVE OIL SEALReplace.Make sure thespring is in the
oil seal. (cont'd)

Rear Suspension
Hub Bearing Unit Replacement (cont'dl
NOTE: Disc type {'99 2D Si and Si-R modets)
1. Loosen the wheel nuts slightly.
2. Raise the rear of vehicle, and support it with safetystands in the proper locations {see section 1).
3. Remove the wheel nuts and rear wheel.
4. Pull the parking brake lever up.
5. Remove the hub cap.
6. Raise the locking tab on the spindle nut, thenremove the nut. SPINDLE NUT22 x 1.5 mrn181 N.m (18.5 kgf'm, 134lbf.fi)Replace.NOT€:. Eefore installing the spindle nut,apply engine oil to the seatingsurface of the nut.. After tightening, use a drift tostake the spindle nut shoulderagainst the spindle.
lFor vehictes \\with drum brakes;/
WHEEL NUT12 x 1.5 mm108 N.m
I I 1 kgt m, 80 lbf.ftl
HUB CAPReplace-NOTE: Take care not to damage the hub untton disassembly.
Remove the 6 mm brake disc retaining screws.7.
6 mm BRAKE DISCRETAINING SCBEWS9.8 N.m 11.0 kgl.m, 7 lbf.frl
1A-24
8.
9.
Release the parking brake lever.
Remove the brake drum, hub unit bearing, andspindle washer lfor vehicles with drum brakes).
BRAKE DRUM
SPINDI-E WASHER
10. Remove the 6 mm flange bolts and caliper shield.
CALIPER SHIELOCheck for bending and damage.
6 mm FLANGE BOLTS9.8 N.m {1.0 kgf.m, 7 lbf,ft)

L
Wheel Soeed and Modulator Contlo
t
OUTLETVALVE ON
OFF
INLETVALVE ON
OFF
t\,40ToR
ON
OFF
when the wheel speed drops sharply below the vehicle speed, the inlet valve closes to retain the caliper fluid pressure
When the wheel speed drops further, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump
motor starts at this time.
As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure.
Wheel SensoJ
The wheel sensors are the magnetic contactless type
As the gear pulser teeth rotate past the wheel sensor's magnetic coil, AC current is generated The AC frequency changes
in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects
the wheel speed.
There are four wheel sensors, one for each wheel
The gear pulser has 50 teeth.
EEL SPEED
at LOW SPEEDgl
=o
GEAR PULSEBWHEEL SENSOBat HIGH SPEED
/
19-49

Overhaul
1.
3.
Pull out the A,/C thermostat sensor from the evapo-
rator fins.
Remove the self-tapping screws and clamps from
the housings.
Carefully separate the housings, then remove the
evaporator.
lf necessary, remove the expansion valve.
NOTE: When loosening the expansion valve nuts, use
a second wrench to hold the expansion valve or the
evaporator pipe. Otherwise, they can be damaged
5. Assemble in the reverse order of disassembly Make
note of following items.
. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage.
. Install the expansion valve capillary tube so that
it is in direct contact with the suction line. Then
wrap wath taPe.
. Reinstall the Ay'C thermostat sensor to its original
location.
6th tin lrom inld side
Serpentine type:
Laminate typo:
TAPEReplace.lvake sure there is no foreign matter stuck between
60t5mml'2.1! O.2 inl
EVAPORATORblow din out of linswith compressed air,
HOUSING
8 N.m 10.8 kgt m,6 tbf.ftl
6th fin lrom outle't sideCAPILLARY TUAE
VALVEN
u'
ll
6\N.m (2.it kgt.m,17 tbtftl1l
A/C THERMOSTfesr page 22 21
%
EVAPORA
LOWER
22-29

9. lf necessary, remove the compressor bracket as fol-
lows.
. Remove the nut and the washer.
NOTE: When tightening the nut of the left front
mount, make sure the washer is set properly on
the left front engine mount as shown.
. Remove the four mounting bolts and the com-
pressor bracket.
12 x 1.25 rrirn59 N.m 16.0 kgt'm,43 tbf.ft)
COMPRESSORBRACKET
WASHER
1.0 x 1.25 mm44 N.m (i1.5 kg{.m, 33 lbl.ft)
LEFT FRONTMOUNT
10. lnstall in the reverse order of removal. Make note of
the following items.
. lf you're installing a new compressor, drain all
the refrigerant oil from the removed compressor,
and measure its volume. Subtract the volume of
drained oil from '130m? 14 1/3 tl'o2,4 6 lmp'oz);
the result is the amount of oil you should drain
from the new compressor (through the suction
fifting).
. Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage
. Use refrigerant oil (SP-10) for R-134a Sanden and
Hadsys spiral type compressors only'
o To avoid contamination, do not return the oil to
the container once dispensed, and never mix it
with other refrigerant oils.
. lmmediatelY after using the oil, replace the cap
on the container, and seal it to avoid moisture
absorption.
. Do not spill the refrigerant oil on the vehicle; it
may damage the painu if the refrigerant oil con-
tacts the paint, wash it off immediately
. Adjust the Ay'C compressor belt (see page 22-43)
and the power steering pump belt (see section 17)'
. Charge the system (see page 22-46), and test its
oerformance (see Page 22-241
22-31

Compressor (DENSOI
Replacement (cont'd)
9. Remove the bolts, the suction service valve and theO-ring from the compressor,
lf necessary, remove the compressor bracket as fol-lows.
. Remove the nut and the washer from the left frontmount. When tightening the nut to the left frontmount, make sure the washer is set p.operly onthe left front mount as shown.
a Remove the mounting bolts and the compressor
bracket.
12 x 1,25 rnm59 N.m 16.0 kgfrm,
10.
LEFT FRONTMOUNT€ rbf.fi)Roplace.
WASHEB
x 1.25 mm
2s.5 N.m {2.6 kgf.m. 18.8 tbtttl
4/r N.m {4.5 kgf.m, 33 lbt ft}
22-3A
1 1. Install in the reverse order of removal, and note thesertems:
lf you're installing a new compressor. drain all therefrigerant oil from the removed compressor. andmeasure its volume. Subtract the volume ofdrained oil from '140 ml (4 28 fl{,z, 4.9 lmpoz); theresult is the amount of oil you should drain fromthe new compressor (through the suction fifting).Replace the O-rings with new ones at each fining,and apply a thin coat of refrigerant oil beforeinstalling them. Be sure to use the right O,ringsfor HFC-134a (R-134a) to avoid leakage.
Use refrigerant oil {DENSO, ND-OtL8) for HFC-134aDENSO piston type compressors only.To avoid contamination, do not return the oil tothe container once dispensed, and never mix itwith other refrigerant oils.
lmmediately after using the oil, replace the capon the container, and seal it to avoid moisture
absorption.
Do not spill the refrigerant oil on the vehicle; itmay damage the paint; if the refrigerant oil con-tacts the paint, wash it off immediatelv.
Adjust the ly'C compressor belt (see page 22-43)and the power steering pump belt (see section 17).Charge the system (see page 22-46), and test itsperformance (see page 22-24!..

1. Inspect the electrodes and ceramic insulator for:
Spark Plug lnspection
Crackedinsulator
2.
[ . t.p,op", grp
| . Oil-fouling
i . Carbon deposits
| . Cracked center
I electrode insulator
Burned or worn electrodes may be causecl by:
. Advanced ignition timing
. Loose spark plug
. Plug heat range too low
. Insufficient cooling
Fouled plugs may be caused bY:
. Retarded ignition timang
. Oil in combustion chamber
. Incorrect spark plug gap
. Plug heat rangetoo high
. Excessive idling/low speed running
. Clogged air cleaner element
. Deteriorated ignition coil or ignition wares
D16Y5, D16Y7, D'16Y8 enginel
. Adjust the gap with a suitable gapping tool, and
replace the plug il the center electrode is round-
ed as shown below.
Electrode Gap:
1.1 mm
{o.{X:l in)ROUNDEDELECTRODE
Standard 1.1r8 ' mm (0.043i800oin)
Worn or detormed
1T
23-111
3. 816A2 engine:
. Do not adjust the gap of a platinum tip plug;
replace the spark plug il the center electrode is
rounded or it the gap is not within the specifica
tro ns.
Electlode Gap:
Standard 1.3181mm (0.051 !3oo" in)
flOUNDED ELECTROOE
',/
@_
:
Platinum tip
NOTE: Use only the spark plugs listed below
4. Apply a small quantity of anti seize compound to
the plug threads, and screw the plugs into the cylin
der head finger-tight. Then torque them to 18 N m
11.8 kgf.m, 13lbnft).
Engine TypesSpark Plugs
D16Y5ZFR4F 11 (NGK)
KJ14CR-111 (DENSOi
D16Y7,
D,I6Y8
ZFRSF-11 (NGK)
KJ16CR-111(DENSO)
81642PFR6L.13 (NGK)
PK2OPR.L13 (DENSO}