D16Y8 HONDA CIVIC 1996 6.G Owner's Guide

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

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

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)
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\^
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
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OOWEL PIN

lllustrated Index
(cont'd)
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft(see page 7,11).identification markings
Lubricate all internal parts with engine oil duringreassembtv.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTON RINGSReplacement. page 7-20Measurement, pages 7 20 andj-21Alignment, page 7-21
PISTON PINRemoval, page 7,17Installation, page 7-18Inspection, page 7,19
CONNECTING RODEnd play, page 7-8Selection, page 7,18
CONNECTING RODBEARINGSClearance, page 7 11Selection, page 7-11
CONNECTING ROD BEARING CAPInstallation, page 7-23NOTE: lnstall caps so thebearing recess is on thesame side as the recessin the rod.
PISTONInspectron, page 7-15NOTE: Betore removing the piston, inspect thetop of the cylinder bore for carbon build-up orridge. Bemove ridge if necessary, page 7-13
ENGINE BLOCKCylinder bore inspection, page 7-16Warpage inspection, page 7,'16Cylinder bore honing, page 7,17
Inspect top of each cylinder borefor carbon build-up or ridgebefore removing piston.Remove ridge if necessary, page 7-13
CONNECTING ROD CAP NUT816A2 €ngin6:9 x 0.75 mm{0 N.m (4.1 kgt m, 30 tbf.ftlD16Y5, Dl6Y7. D16Y8 engines:8 x 0.75 mm3l N.m {3.2 kg{.m,23 tbt.fr)Apply engine oiltothe bolt threads.NOTE: After torquing each bearingcap, rotate crankshaft tocheck for binding.
7-6

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

Main Bearings
4.
Glearance
1.To check main bearing-to-journal oil clearance.
remove the main caps and bearing halves.
Clean each main journal and bearing half with a
clean shop towel.
Place one strip of plastigage across each main jour-
na l.
NOTE: lf the engine is still in the car when you bolt
the main cap down to check clearance, the weight
of the crankshaft and flvwheel will flaften the plasti-
gage further than just the torque on the cap bolt.
and give you an incorrect reading. For an accurate
reading, support the crank with a jack under the
counterweights and check only one bearing at a
time,
Reinstall the bearings and caps, then torque the
bolts.
lst step: 25 N'm (2.5 kgl'm. 18 lbf'ft)
FinalsteD:
B16A2 engine:
76 N.m (7.8 kgf.m, 56 lbf'ft)
D16Y5, Dl6Y7, D16Y8 engines:
51 N.m (5.2 kgf'm, 38 lbf'ft)
NOTE: Do not rotate the crankshaft during inspec-
tron.
Remove the cap and bearing again, and measure the
widest part ot the plastigage.
Main Boaring-toJournal Oil Clearance:
816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l - 0.042 mm 10'00(B - 0.0017 in)
No. 3 Journals:
0.030 - 0.048 mm {0'0012 - 0'0019 in)
Servico Limit: 0.06 mm {0.002 in,
Dl6Y5, Dl6
r, Dl6Y8 engines:
Standard (Nsw):
No. 1,5 Journals:
0.018 - 0.035 mm {0.0007 - 0'001'[ in)
No. 2. 3, 4 Journals:
0.02,1 - 0.0,(2 mm {0'0009 - 0.0017 in}
Service Limit: 0.05 mm (0.002 in)
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7-9
7.
lf the plastigage measures too wide or too narrow,
(remove the engine if it's still in the car), remove the
crankshaft, and remove the upper half of the bear-
ing. Install a new. complete bearing with the same
color code {select the color as shown on the next
page), and rechsck the clearance.
CAUTION: Do nol fil€, shim, or scrape the bearings
or tho cap3 to adiust cleatanc€.
lf the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color
listed above or below that one), and check again
NOTE: lf the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

Main Bearing
Selection
CAUTION: lf the codes are indecipherable because of anaccumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent ol
deiergent.
Crankshaft Bore Code Location
81642 engine:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers or bars stamped on the
crank {codes for main journal size), to choose the correct
beaflngs.
Main JournalCode Locations {Nombers or Barc)
Eearing ldentificationColor code rson lhe edge ofthe bear ng.Larger crank bore
acD
-----------""' Smallerbeanngtlhrcker)
9""1B':""
Alack
Black
Alue
7-10
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D16Y5, D16Y7, D16Y8 engines:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers stamped on the crankshaft(codes for main journal size), to choose the correct bear-
Ings.
Main Journal Code Location (Numbers)
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Color codeon theedge ofthe bearing-
Ldrger crank bore
Smaller bea ng {th'cker)
lr-l
t#lt+,tlf l 4 tlf '- 't
Smaller Smallermaan bearingjournal {thicker)
RedPinkGreen
PinkGreenBrown
GreenBrownBlack
GreenBrownBlackElue
I
Bearing ldentification
BcD

Connecting Rod Bearings
Clearance
Remove the connecting rod cap and bearing half
Clean the crankshaft rod iournal and bearing half
with a clean shop towel.
Place plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the nuts.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and bearing half and measure
the widest part of the plastigage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engine:
Standard lNewl: 0.032 - 0.050 mm
10.0013 - 0.0020 in)
Service Limit: 0.06 mm 10.002 inl
D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 0.020 - 0.038 mm
(0.0008 - 0.0015 in)
Service Limit 0.05 mm 10.002 inl
'1.
4.
lf the plastigage measures too wide or too narrow'
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown in the right column), and
recheck the clearance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf the plastigage shows the clearance is still incorrect.
try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.
NOTE: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
PLASTIGAGE STRIP
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7.
7-11
Selection
CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not sclub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the side of each con
necting rod as a code for the size of the big end Use
them, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearlngs
Half of number ls
stamped on bearingcap and the otherhalf is stamped onrod.
Bearing ldentilication
Color code is on theedge ofthe bearing.
lfA--;T] |
lle"'tt l;llcorlll ll
I lD;;ilril |l-l
Larger brg end bore
Smaller Smallerrod bearlngjournal (thicker)
---------------- Smallerbearing{thrcker)
RedPinkGreen
PinkGreen
GreenErownBlack
GreenBrownBlackBlue
1234
Connecting Rod Journal Code Locations (Lettels)

Pistons and Crankshaft
Removal
1. Remove the oil pan assembly.
2. Remove the right side cover.
816A2 engine
D16Y5, Dl6Y7, D16Y8 ongines
RIGHT SIDE
7-12
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3. Remove the oil screen.
4. R€move the oil pump.
816A2 engin€
OIL SCREEN
D16Y5, D1oyr, D16Y8 engin.s
O-RINGReplace.
5, Remove the baffle plate (816A2 engine).
OIL PUMP

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)
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