plate HONDA CIVIC 1996 6.G User Guide

Rocker Arms
Disassembly/Reassembly (cont'dl
NOTE:
. ldentify pans as they are removed to ensure reinstallation in original locations.. Inspect rocker shafts and rocker arms (see page 6-34).. Rocker arms must be installed in the same position if reused.t when removing or installing the rockerarm assembly, do not remove the camshaft holder bolts. The boltswill keeptheholders, springs and rocker arms on the shaft.
I erior to reassembring, crean a

the parts in sorvent, dry them and appry rubricant to any contact points.
D16Y5 engine:
ROCKER ARMS
TIMING PLATERUBBER BANO
(\
-]-
-P'g,rpt+.t't ll
\--,?|, -\2i lNo.5 CAMSHAFT _ lHOLDER l
No. 4 CAMSHAFTHOLDERNo. 3 CAMSHAFIHOLDERNo.2HOLDER
ra
I
EXHAUST ROCKERARM B{,1 plac€s)
EXHAUST ROCKEE SHAFT
Letter "A" is slamped
II{TAKE ROCKER SHAFT
!-r I
?h'ffi*ffi'
/^ ---IOCKER SHAFT
Letter "8" is stamped
6-32

Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, Dt6Y8 enginesl
NOTEr When reassembling the primary rocker arm,carefully apply air pressure to the oil passage of therocker arm.
1. Inspect the rocker arm piston. push it manually.- lf it does not move smoothly, replace the rockerarm assembty.
Dl6Y5 engine:
ROCKER ARM
TIMING PISTON
TIMING SPRING
SYNCHRONTZINGPISTON
SECONDARYROCKER ARM
MID ROCKER ARM
PRIMARY ROCKER
SYNCHRONIZINGPISTON A
NOTE:
. Apply oil to the pistons when reassembling.o Bundle the rocker arms with a rubber band to preventthem from separating.
6-34
(\
DI6YS engine:
NOTE: Set the timing plate and return spring as shownoerow.
RETURN
CAMSHAFT HOLDER
Dl6Yg engine:
2. Remove the lost motion assembly from the holderand inspect it. Test it by pushing the plunger withyour finger.- lf the lost motion assembly plunger does notmove smoothly, replace it.
LOST MOTION ASSEMBLY
\a
Pu3h
I

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

Crankshaft PulleY and PulleY Bolt
Replacement
When installing and tightening the pulley, follow the procedure below'
Clean, remove any oil, and lubricate points shown below
a: Cleanx : Bemove anY oll
a: Lubricate
PULLEY BOLT
WASHER TIMIIGUID
Crankshaft pulley bolt size and torque value:
14 x 1.25 mm
177 N.m t18.0 kgtm, 130 lbf'ftl
NOTE: Do not use an impact wrench when installing'
XX
XXxx
Ii
x
XXXXXX
BELTGUIOE PLATE
PULLEY HOLO€R ATTACHMENT,50 mm07JAB - 0O10,OA
CRANKSHAFT
XXXXX
6-59

Cylinder Head
19.
20.
Removal (cont'dl
Remove the timing belt {see page 6-62).
Remove the back cover and camshaft pulleys.
BACK COVER
56 N.m (5.7 kgf m,
41 tbt.f06xl.0mm9.8 N,m (1.0 kgf.m, 7.2 lbf.ft)
21, Remove the exhaust manifold (see page 9-8).
22. Remove the intake manifold (see page g-5).
23. Loosen the adjusting screws.
INTAKE
No.4 No.3 No.2 No. 1
6-70
24. Remove the camshaft holder plates, camshaft hold-ers and camshafts.
CAMSHAFTHOLDER PLATE
Remove the cylinder head bolts, then remove the
cylinder head.
CAUTION: To prevsnt warpage. unscrew the bolts
in sequonc€ 1/3 turn at a tim€; lepeat lh6 sequence
until all bolts aro loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE:
CYLINDER HEADPLUGReplace. t
\1
\€\i
b4CAMSIIAFTS -

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-<

Engine Block
Speciaf Tools ..........." 7-2
lllustlated Index ...................."..'.......... 7-3
Flywheel and Drive Plate
Repf acement """'.' 7-7
Connecting Rod and Crankshaft
End Play ..........."....7-8
Main Bearings
Clearance ............... 7-9
Selection ................7-10
Connecting Rod Bearings
clearance ....'.......... 7-11
Selection ................ 7-11
Pistons and Crankshaft
Removaf ................. 7 -12
Crankshaft
Inspection ."".........7-14
Pistons
Inspection ......"'.....7-15
fnstaffation .............7-23
Cylinder Block
lnspec'tion ..............7-16
Bore Honing ..........7-17
Piston Pins
Removal ...,...........'.7-17
lnstallation .............7-18
Inspection .'............7-19
Connecting Rods
Selection ................7-18
Piston Rings
End Gap ..........".."' 7'2O
Repfacement .........7-2O
Ring-to-Groove Clearance ...........'.'. 7 -21
Afignment .......""'.. 7'21
Crankshaft Oil Seal
fnstaffation .............7-22
Crankshaft
fnstaffation ..-.-..'.".' 7'23
Oil Pan
lnstallation .............7-26
Oil Seals
fnstaffation ....""""' 7-29
r-f

lllustrated Index
I runricate att internal parts with engine oil during reassembly'
NOTE:
o Apply liquid gaskettothe mating surfaces ofthe right side cover and oil pumpcase before installingthem'
. Use liquid gasket, part No 08718-0001 or08718-0003'
. Clean the oil pan gasket mating surfaces betore installing the oil pan
81642 engine:
DRAIN BOLT44 N,m {4.5 kgf'm,33 lbt'ft)
6 x 1.0 mm'11 N.m (1.1 kgI'm,
I tbl.ft)
OIL PANReter to page 7 27when installing.
6 r 1.O mm12 N.m t1.2 kgl'm, 8 7 lbf'lt)
OIL PAN GASKET
BUFFLE PLA
12 x 1.0 mm103 N.m {10.5 kgf'm,
76 tbr.ft)
6 x 1.0 mm11 N.m (1 .1 kgf.m,
8 tbI.fr)
GASKETReplace.FLYWHEEL(M/TI
12 x 1.0 mm
74 N.m (7.5
kof.m, 54 lbf'ft)
1^c{Eb\%^ t*^
*o"rr^--(Wffi
oa*,trto2,.w
FLYWHEEL COVER
IM/T)
DRIVE PLATECOVER (AiT)
11 x 1.5 mm76 N.m (7.9 kgf'm, 56 lbf'ft)
Apply engine oil to the bolt
threads.NOTE: After torqurngeach cap, turn crankshaft
to check for binding.
MAIN EEARING CAP
MAIN BEARINGSSelection, page 7_10
NOTE: New main bearings musl
be selected bY matching crank
and block identification markrngs
CRANKSHAFTInstallation, Page 7'23
OIL JET BOLT16 N.m 11.6 kgf'm, 12 lbl'ft)
OIL JETInspection, Page 8_10
Check for cracks
6x1.0mm11 N.m {1.1 kgf'm, I lbf'ft}
CRANKSHAFT OIL SEAL
Installation,pagesl 22 andl 29
Replace-
DOWEL PINOIL PUMPOverhaul, page 8-'l1Removal/lnspection,page 8-13.Apply liquid gasket
to mating surlace.RIGHT SIDE COVERApply liquid gasket
to mating surface.
THRUST WASHERS8 x 1.25 mm24 N.m {2.4 kgf.m, 17 lbf'ft)Grooved sides face outward
NOTE: Thrusr washer thickness
is tixed and must not be changed
by grinding or shimming
O-RINGReplace
CRANKSHAFT SEAL11 N.m {1.1 kgf'm, lnstallation, pages 7'29 and I 14
a lbt.ltl Heplace. (cont'd)
d#*

D16Y5, D16Y8 engines:
DRAIN BOLT39 N.m 14.0 kgt'm,
Apply liquid gasket to
these points.
OIL PANRefer to page 7-25
when installing.WASHERReplace.
29 lbl.tt)
\
\^
6 x 1.0 mm q%
P
I
FLYWHEEL COVER(M/T}
12 x 1.0 mm118 N.m(12.0 kgt.m, 87 lbt'ft)
FLYWHEEL (M/TI
t2 N.m 11.2 kgf'm,
8.7 lbl.ftl
11 x 1.5 mm
51 N.m(5.2 kgf'm, 38 lbf ftl
Apply engine oiltothe bolt
threads.NOTE: Aftertorquingeach cap, turn crankshaft
to check for binding.
MAINBEARING
MAIN BEARINGSSelection, page 7-10NOTE: New main bearings must
be selected by matching crank
"nJ lr."i io"irriti"",ion-markings. --------*-i6{\
CRANKSHAFTInstallation, page 7-23
6 r 1.0 mm11 N.m (1 1 kgf'm, I lbf'ttl
OII PAN GASKETReplace.
DRIVE PLATE COVER
{A/T or CVT)
12 r 1.0 mm
74 N.m
17.5 kgl.m, 54 lbf'ft)
DBIVE PLATE {A/T or CVTI
Check for cracks
6 x 1.O mm11 N.m {1.1 kgl'm,
8 tbl.ftl
CRANKSHAFT OIL SEAL
lnstallation,pages 7'?1 and '1 '28
Replace.
RIGHT SIDE COVER
Apply liquid gasket
to mating surface.
OIL SCREEN
GASKETReplace.
OIL PUMPOverhaul, page 8_12Removal/lnspection,page 8-13Apply liquid gasket
to mating surface.
DOWEL PIN
WASHEFS
Grooved sides tace outward
NOTE: Thrust washer thickness
is fixed and must not be changed
bV grinding or shimming.
CRANKSHAFT SEALInstallation, pages 7 29
and 8-14Replace.
BREATHING PORT COVER
MOUNT BOLTS6 x 1.O mm11 f{..n (1.1 kgf'm, 8 lbf'fl)
Apply liquid gasket to
the bolt threads.
O.RINGReplace.
6 x 1.0 mm
11 N.m (1 1 kgl'm,
8 tbr.ftl
(cont'd)
7-5
\
OOWEL PIN

Flywheel and Drive Plate
Replacement
Manual Transmission:
816A2 engine:
Remove the eight flywheel bolts, then separate the fly-
wheel from the crankshaft flange. After installation'
tiohten the bolts in the sequence shown
RING GEAR HOLDER "-i
OTLAB PVOOlOO
D16Y5, D16Y7, D16Y8 engines:
Remove the six flywheel bolts, then separate the flywheel
from the crankshaft flange. After installation, tighten the
bolts in a crisscross Pattern.
RING GEABInspect ring gear
teeth lor wear or
damage.
RING GEARInspect ring gear
teeth lor wear orteetn lor wea( or /danase. ,///.'
12 x 1.0 mm103 N.m(10.5 kgf.m, 76 lbf.tt)
12 x 1.o mm1 18 N,m(12.0 kgI.m, 87 lbf.ftl
L
rurS;u'.\
$..3s'
Automatic Transmission:
Remove the six drive plate bolts, then separate the drive
olate from the crankshaft flange. Atter installation, tighten
the bolts in a crisscross Pattern.
t7.5 kgl.m, 54 lbl'ltl
12 x 1.0 mm74 N.m
7-7