replace HONDA CIVIC 1996 6.G Manual Online

OilJet (B1642 engine)
Inspection
1.Remove the oil jet (see page 8-3) and inspect it asfollows.
Make sure that a 1.1 mm (0.04 in) diameter drillwill go through the nozzte hole (j.2 mm (0.05 in)diameter).
Insert the other end of the same 1.1 mm (0.04 in)drill into rhe oil intake (i.2 mm (0.05 in) diame_ter).
Make sure the check ball moves smoothly andhas a stroke of approximately 4.0 mm (0.16 in).Check the oil jet operation with an air nozzle. ltshould take at least 200 kPa (2.0 kgf/cm,, 28 psi)to unseat the check ball.
NOTE: Replace the oil jet assembly if the nozzlers damaged or bent.
CHECK BALLSPRING16 N.m 11.6 kgf,m, t2 tbf.fil
Mounting torque is critical. Be very precise wheninstalling.
Torque: 16 N.m (1.6 kgt.m, 12 tbt.ft)
1.2 mm (0.05 inl
8-10

Oil Pump
Overhaul
NOTE:
. Use new O rings when reassembllng.
. Apply oil to O-rings before installation.
. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003
. The rotors must be installed to the same direction in order'
o After reassembly, check that the rolors move without binding'
B15A2 engine:
6x1.0mm7 N.m (0.7 kgf m, 5 lbf ft)
OUTER ROTORInspection, page 8-13
INNER ROTORpage 8-13
OOWELPIN
O-RINGReplace.
6x1.0mm11 N.m (1.1
8 tbtfrlkgf.m,
PUMP HOUSINGInspection, page 8-13
Apply liquid gasket
to the mating surface of
the cylinder blockwhen installing.
8 x 1.25 mm24 N,m {2.i1 kgl.m.
17 tbf.ft)RELIEF VALVEValve mlst slide freeiy
in housing bore.Replace if scored.OIL SEALReplace.lnstallation,page 8-14
SEALING BOLT39 N.m l4O kgt'm,29 tbt frl
\(cont'd)
SPRING
8-11

Oil Pump
Overhaul (cont'dl
NOIE:
. Use new O rings when reassembling.. Apply oil to O rings before instalraUon.. Use liquid gasket, Parr No. 08718 - 0001 or08718_0003.. The rotors must be installed to the same direction.. After reassembly, check that the rotors move without binding.
D16Y5, D16Y7, D16Y8 engines:
(
6x1.0mm7 N.m (0.7 kgI.m, 5 lbf ftl
PUMP HOUSINGInspection, page 8 13Apply liquid gasketto mating surface ofthe cylinder biockwhen installing.
INNER ROTORInspectron, page 8 13
DOWEL PIN
PUMP COVEB
O-RING
_.feor,""
\6x1.0mm11 N.m {1.1 kgf.m,8lbl.ft)RELIEF VALVEValve must slide freelyin housing bore.Replace if scored
OIL SEAL
[".?li;:;"". *,", ,.rg
""rc
@.-*or"."
9''ggttt*
8-12

4.
Removal/lnspection/lnstallation
2.
3.
1.
5.
6.
1.
8.
Drain the engine oil.
Turn the crankshaft and align the white groove on
the crankshaft pulley with the pointer on the lower
cover.
Remove the cylinder head cover and upper cover'
Remove the power steering pump belt, air condi-
tioner beit and the alternator belt
Remove the crankshaft pulley and remove the lower
cover.
Remove the timing belt.
Remove the drive pulley.
Remove the oil pan and oil screen.
O.RINGReplaceOOWEL PIN
OIL SCREEN
9. Remove the oil PumP.
!'a
10.Remove the screws from the pump housing, then
separate the housing and cover'
Check the inner-to-outer rotor radial clearance on
the pump rotor. lf the inner-to outer rotor clearance
exceeds the service limit, replace the inner and
outer rotors.
lnner Rotor-to-Outer Rotor Radial Clearance
Standard {New}: 815A2 engine 0.04 - 0.16 mm
(0 002 - 0'006 in)
D16Y5, D16Y7, D16Y8 engines
0.02 - 0.14 mm 10.001 - 0.006 in)
Service Limit: 0.20 mm (0 008 inl
OUTER ROTOR
INNER ROTOR
Check the housing-to-rotor axial clearance on the
pump rotor. lf the housing-to rotor axial clearance
exceeds the service limit, replace the set of inner
and outer rotors and/or the pump housing
Housing-to-Rotor Axial Clearance
Standard (N€w): 816A2 engine 0.02 - 0.07 mm
(0.001 - 0.003 inl
D16Y5, D16Y7, D16Y8 engines
0.03 - 0.08 mm (0.001 - 0.003 inl
S€rvice Limit: 0.15 mm 10.006 in)
11.
't2.
(cont'd)
8-13

Oil Pump
RemovaUlnspection/lnstallation (cont'dl
13. Check the housing-to-outer rotor radial clearance.lf the housing-to-outer rotor radial clearanceexceeds the service limit, replace the set of innerand outer rotors and/or the pump housing.
Housing-to-Outer Rotor Badial Clearanco:Standard {Newl: 816A2 sngine 0.10 - 0.19 mm(0.004 - 0.007 in)
D16y5, Di6y7, Dt6y8 engines0.10 - 0.18 mm {0.00it _ 0.007 in)Service Limit: 0.20 mm (0.008 in)
lnspect both rotors and pump housing for scoringor other damage. Replace parts if necessary.
Remove the old oil sealfrom the oil pump.
Using the special tool, gently tap in the new oil sealuntil the driver bottoms against the pump.
NOTE: The oil seal alone can be replaced withoutremoving the oil pump.
DRIVER ATT52x55mm077a6 - 0010ao0
14.
15.
16.
8-14
PUMP HOUSING
17. Reassemble the oil pump, applying thread lock tothe pump housing screws.
18. Check that the oil pump turns freely.
19. Apply a light coat of oilto the seal lip.
20. Install the two dowel pins and new O-ring on the oilpump.
21. Apply liquid gasket to the cylinder block mating sur_face of the oil pump.
NOTE:
. Use liquid gasket, Part No.08718 - oOOj or 08718- 0003.. Check that the mating surfaces are clean and drybefore applying liquid gaskel. Apply liquid gasket evenly, in a narrow bead cen-tered on the mating surface.o To prevent leakage of oil, apply liquid gasket tothe inner threads of the bolt holes.. Do not install the parts if five mtnures or morehave elapsed since applying liquid gasket.Instead. reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
81642 engine:
\
D16Y5, D16Y7, D16Y8 engines:
along the broken line.

22. Installthe oil pump on the cylinder block.
Apply grease to the lip ot the oil pump seal.
Then. install the oil pump onto the crankshaft.
When the pump is in place, clean any excess grease
off the crankshaft and check that the oil seal lip is
not distorted.
81642 engine:
8 x 1.25 mm6x1.Omm
24 N.m (2.i4 kg[.m,17 tbl.trl
11 N.m {1.1 kg{.m,8 rbt ft)O.RI GReplace.
DOWEL PINS
GASKETReplace.
OIL SCREEN
6x1.0mmrl N.m {1.1 kgf'm,I tbf.ftl
D16Y5, D16Y7. D16Y8 enginos:
OOWEL PIN
6x1.0mm11N'm (1.1 kgf m'
O.RINGReplace.
DOW€L PIN
GASKETReplace.
6x1.0mm
6 x 1.0 mm '11 N'm {1 1 kgf'm,
11 N.m (1.1 kgf.m, I lbf ftl
8 lbf.ft)
!o
8-15
lnstall the oil screen.
Install the oil pan (see pages 7-26 or 7-27).
NOTE: Clean the oil pan gasket mating surfaces.

lntake Manifold/Exhaust System
lntake Manifold
Replacement ....................................... 9-2
Exhaust Manifold
Rep|acement ....................................". 9-6
Exhaust Pipe and Muffler
Replacement ...............................'.'.".. 9-9
Three Way Catalytic Converter {TWCI
Inspection .................."'. 9-12
Heated Oxygen Sensor (HO2SI
Rep|acement ...........................'.."....." 9-12
L_s
r f o

Intake Manifold
Replacement
NOTE: Use new O-rings and gaskets when reassemblinq.
CAUTION:
. Check tor folds or scratchos on the surface of tbe gasket.. Replace with a now gasket if damaged.
D16Y7 engine:
8 x 1.25 mm22 N.m 12.2 kgtm, 16 tbtftl
INTAKE MANIFOLDReplace if cracked orif mating surfaces aredamaged.
8 x 1.25 mm23 N.m {2,3 kgt m.17 rbf.ftl
INTAKE MANIFOLDBRACKET
8 x 1.25 mm24 N.m {2.4 kgf.m, 17 tbf.ftl
9-2

D16Y5 engine:
6x1.0mm12 N'm (1.2 kgl.m,8.? lbf'ft)
EGR CHAMBER
INIAKE MANIFOLDReplace if cracked orif mating surfaces are8 x 1.25 mm21 N m (2.1 kgf.m,15 tbtft)damageo,
INTAKE AIB CONTROL(IAC) VALVE (M/TI
8 x'1,25 mm22 N.m (2.2 kst m, 16lblftl
8 r 1.25 mm2a N.m (2.4 kgt m,17 rbt.ft)
EXHAUST GASRECIRCULATION(EGRIVALVE
8 x 1,25 mm22 N.n 12.2 kol'm,16 tbftr)
INTAKE MANIFOLDBRACKET
8 x 1.25 mm23 N.m 12.3 kgf'm,17 tbt fr)
(cont'd)I
9-3

lntake Manifold
Replacement (cont'dl
NOTE: Use new O,rings and gaskets when reassembling.
CAUTION:
. Check lor folds or scratches on the surface of the gasket.. Replace with a new gasket il damaged.
D16Y8 engine:
INTAKE MANIFOLDReplace if cracked orif mating surfaces areoamageo,
INTAKE AIR CONTROL{ract vAt_vE {M/Tl
GASKETReplace.
8 x 1.25 mm24 N.m {2.{ kgtm.17 tbtftt
THROTTLEBODY
8 x 1.25 mm22 N.rn |.2.2 kgl.rn,16 tbtft)INTAKE MANIFOLDBRACKET
9-4