engine removal HONDA CIVIC 1996 6.G Service Manual

Intake Air System
J
Throttle Body (cont'dl
Removal
D16Y5, Dl6Y8, 81642 engine:
D15Y7 engine:
AIR CLEANER
{ACLI
22 N.m12.2 kgl.m,16 rbf.ftl
NOTE:
. Do not adjust the throttle stop screw.. After reassembly, adjust the throttle cable {see page l l-244).. The TP sensor is not removable.
IAT SENSOR
MAP SENSOR
GASKETReplace.
11-248
THROTTLE CABLE

Pressure Plate
\Removal/lnsPection
1.Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard {New}: 0.6 mm (0.02 inl max.
Seruice Limit: 1.0 mm {0.04 in}
FEELER GAUGE
CLUTCH ALIGNMENT DISCOTJAF_PM7O1 1ACLUTCH ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-37tOtOO
lf the height exceeds the service limit, replace the
pressure Plate.
3. Installthe special tools
PRESSURE PLATE
MOUNTINGBOLT
ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-371010Oo7924-PD20003GEAR HOLDER
07LA8-PVOOIOOot
ENGINEBLOCKADJUSTER BOLT
BOLT
4. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
f
12-7
lnspect the pressure plate surface for wear' cracks,
and burning.
Inspect for warpage using a straight edge and leeler
ga uge.
NOTEr Measure across the pressure plate at three
pornrs.
Standard (Newl: 0.03 mm (0.001 inl max.
Service Limit: 0.15 mm (0.006 inl
lf the warpage exceeds the service limit, replace the
pressure plate.
STBAIGHT EDGE

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)

Transmission Assembly
Removal(cont'd)
17. Remove the three upper transmission mounting
bolts and the lower starter mounting bolt,
STARTERMOUNTINGBOLT10 x 1.25 mm44 N.m (4.5 kgf.m,33 rbnftl
TRANSMISSIONMOUI{TING EOLTS12 x 1.25 mm& N.m (6.5 kgt'm,47 lbl.ftl
18. Remove the rear mount bracket bolts and transmis-
sion mounting bolts.
12 x 1.25 mm64 N.ft 16.5 kgl.m,47 lbl.ftl
SPECIAL BOLTReplace.'ll x 1.5 mm84 N.m (8.5 kgf.m, 61 lbf.ftl
SPECIAL BOLTReplace.14 x 1,5 mln84 N.m (8.5 kgl.m, 61
WASI{ERREARMOUNTBRACKET
rbl.ftt
Pull the transmission away from the engine until it
clears the mainshaft. then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.
1(|
Installation
Install the transmission assembly in the reverse order of
removal.
Before installing, check that the two dowel pins are
installed in the clutch housing.
When installing the starter cable, make sure that the
crimped side of the ring terminal is facing out (see
section 23).
Apply grease to the parts as shown, then install the
release fork and release bearing,
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
RELEASE FORK BOLT12 x 1.25 mm29 N'm 13.0 kgt,m,(P/N 08798-90021
22 tbl.ttlR€LEASEBEARING
J
RELEASEFORK8()07
ra
{PiN 08798-9002)
tP/N 08798-900210.3-0.9 g
10.01-0.03 ozl

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

Transmission
Removal
@Maks sure lifts, iacks and safety stands are placedproperly, and hoist bracket ate aftached to the cor_rec{ position on the engine lsee section 1).Apply parking brake and block rear whoels so vehiclewill not roll off stands and fall on you while workingunder it.
CAUTION: Use tender covers to avoid damaging paint-ed surfaces.
1, Disconnect the battery negative (_) terminal fromthe battery, then remove the positive (+) terminal.
2. Remove the intake air duct.
D16Y7 engins:
Remove the intake air duct and resonator.
D16Y8 engine:
Remove the intake air duct and the air cleaner hous-ing assembly,
3. Remove the starter cables and cable holder fromthe starter motor.
MOTOR CABLE
MOTOR CABLE
14-122
4. Remove the transmission ground cable, and discon_nect the lock-up control solenoid connector.
LOCK.UP CONTROLSOLENOID CONNECTOR
5, Disconnect the vehicle speed sensor (VSS) connec_tor and the countershaft speed sensor connector.
VEHICLE SPEED

Transmission
Removal(cont'd)
'10. Remove the cotter pins and castle nuts, th€n separatethe balljoints from the lower arms (see section 1gl.
DAMPER PINCH BOLT
NUT
FORI(FORK BOLT
11. Remove the right damper fork bolt. th€nright damper fork and dampor.
COTTER PINReplace.
separate
12.
1a
14.
Pry the right and left driveshafts out ofthe differential.
Pull on the inboard joint to remove the right and leftdrivsshafts (see section 16).
Tie plastic bags over the driveshaft onds.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A,
NOTE: Dl6YB engine is shown; D16y7 engine issimilar.
t9.
SELF-LOCKING NUTReplace.
L
14-124
EXHAUST PIPE AMOUNT/BRACKET
17.
18.
16. Remove the shift cable cover. then remove the shiftcable by removing the control lever,
CAUTION: Take car6 not to bond the shift cable.
Remove the right front mounvbracket.
Remove the ATF cooler hoses at the ATF coolerlines. Tufn the ends of the ATF cooler hoses uo toprevent ATF from flowing out, then plug the ATFcooler hosgs and lines.
NOTE: Check for any sign of leakage at the hoseioints.
WASHER

Transmission Housing
Removal
MAINSHAFT
TRANSMISSION HOUSINGMOUNTING BOLTS18 Bolts
TRANSMISSIONHANGERTRANSMISSION HOUSING
MAINSHAFTSUB.ASSEMBLY
SENSOR WASHERlD16Y7 engine)
MAINSHAFTSPEED SENSOR
TRANSMISSIONHOUSING GASKETDIFFEBENTIALASSEMBLY
TOROUE CONVERTERHOUSING
SUB.ASSEMBLY
L,
14-134

Transmission
Removal
@. Mako suro lifts. iacks, and satety stands are placod
properly, and hoi3t bracket are attached to lhe cor-
rect position on the engine {see soction 1}.
. Apply parking brake and block r€ar wheels so tha
vehicle will not roll off stands and fall on you while
working undor it.
CAUTION: Use tender covers to avoid damaging painted
surfaces.
Disconnect the battery negative (-) terminal from
the battery, then remove the positive (+)terminal.
Remove the intake air duct and air cleaner housing
1.
assembly.
3. Remove the starter cables and cable holder from
the starter motor.
STARTER CABLE
STARTER MOTOR
14-304
4, Disconnect the solenoid harness connector, the drivepulley speed sensor connector, and the ground cable
terminals.
DRIVE PULI.-EYSPEED SENSORCONNECTOR
SOLENOIO HARNESSCONNECTOR
Remove the clip, then separate the shift cable from
the control lever,
CAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
GROUND CAELE
CONTROL LEVER
S}IIFT CABLE

Transmission
Removal (cont'd)
10. Remove the cotte. pins and castle nuts, then separatethe ball joints from the lower arm (see section 1g).
SELF-LOCKING -=V,
NUT \Replace. oitupea rOax
Remove the right damper fork bolt, then separateright damper fork and damper.
Pry the right and left driveshafts out of the differen-tial.
Pull on the inboard joint to remove the right and leftdriveshafts (see section 16).
Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A.
/\<,\CASTLE I{UT COTTERReplac6.
't 1.
't2.
tJ.
14.
q.
SELF.LOCKINGNUTReplace.
SELF.LOCKING NUTReplace.
14-306
EXHAUST PIPE A
19.
'16, Remove the right front mounvbracket,
ATF COOLER HOSE
17. Remove the ATF cooler hoses at the ATF coolerlines. Turn the ends of the ATF cooler hoses uo toprevent CVT fluid from flowing out, then plug theATF cooler hoses and lines,
NOTE: Check for any sign of leakage at the hosejoints.
18. Remove the engine stiffeners and the flywheel cover.
Remove the eight drive plate bolts one at time whilerotating the crankshaft pullev.
ENGINE STIFFENER