6-20 HONDA CIVIC 1996 6.G Workshop Manual

Cylinder Head/Valve Train
Dl6Y5, D16Y7, Dl6Y8 engines
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection ............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5 engine) ............................. 6-7
Manual Inspection
(D16Yg enginel ................'............ 6-7
Inspection Using Special Tools
{D16Y5 engine} .....................""'... 6-8
Inspection Using Special Tools
(D16Y8 engine) .........................'.'. 6-10
Valve Clearance
Adiustment ..."".....6-12
Valve Seals
Replacement (Cylinder head removal
not requiredl ................................ 6-1tl
Crankshaft Pulley and PulleY Bolt
Replacement ."...... &16
Timing Selt
lllustrated Index ............................... 6-17
Inspection .............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal ......,,......... 6-19
lnstallation ............. 6-20
Crankshaft Speed Fluctuation (CKF) Sensor
Repf acement .........6'22
Cylinder Head
lllustrated Index ............................... 6-23
Removal ................. 6-27
Warpage ................ 6-40
lnstallation ............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly ............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, D16Yg
enginesl "..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection .............. 6-36
Valves, Valve Springs and Valve Seals
Removal ........""..... 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement .........6-41
Reaming .......'......'.' 6-43
Valve Seats
Reconditioning .'....6'40
Valves
lnstallation ............. 6-tt3
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
lnstallation ............. 6-44

Timing Belt
Illustrated lndex
NOTE:
. Refer to page 6-20 for how to position the crankshaft and pulley before installing the belt.
. Mark the direction of rotation on the belt before removing.
a Do not use the upper cover and lower cover for storing removed items,
. Clean the upper cover and lower cover before installing.
. Replace the ca mshaft seals and cra n kshaft sea ls if there is oil leakage.
. Refer to page 6-16 before installing the timing belt.
CYLINDER HEADCOVERReler to page 6-46when installing.
HEAD COVEB GASKETReplaco when l6akin9,domaged or deteriorated.Apply liquid gasket at
th€ lour corners of thetecessos.
d
@
TIMING BELTInspection, page 6-18Adjustment, page 6-18Removal, page 6-19Installation. page 6-20
I x 1.25 mm3t N.m {3.8 kgf'm, 27 lbfftl
Apply engine oilto the bolt
thleads.
CRANKSHAFT SPEED FI.UCTUATION
lcr(Fl sENsoRReplacement, Page 6-22
UPPER COVEB
lnstallwithsurface facing in.
TIMING BELTDRIVE PULLEYReplacement, page 6_16
6x1.0mm9.8 N'm 11.0 kgt m,7.2 tbf.ft)NUBBER SEALSReplace when damagedor deledorated.
LOWER COVER
FUBBERPLUG
CRANKSHAFT PULLEYReplacement, page 6'16
PULLEY BOLTlil x 1.25 mm20 N.m 12.0 kgt.m,14 lbt'ft) + 90"Replacement, page 6'16Do not us6 an impactwrench when installing.
x 1.0 mmBOLT o-RING10 x 1,25 mm Reolace.14 N.m {,1.5 kgt m, 33 lbt ftl
6x1.0mmt2 N.m 11.2 kgf'm,8.7 tbt f0
9.E N'm (1.0 kgt.m,?.2 tbf.ftl\.-,o
6-17

Timing Belt
Removal (cont'd)
9. Remove the CKF sensor from the oI pump.
10. Loosen the adjusting bott lgO..to remove tension from theretighten the adjusting bolt.
12 N.m 11.2 kgt.m,8.7 rbf.ftl
Push the tensioner
timing be lt. then
AD.'USNNG BOLT4{ N.m 14.5 kgt m,33 tbtftl
1 1. Remove the timing belt.
6-20
lnstallation
Install the timing belt in the reverse order of removal;Only key points are described here.
l. set rhe timing belt drive pulley so that the No. 1 pis-ton as at top dead center (TDC), Align the groove onthe timing belt drive pulley to the pointer on the oilpump.
TDC MARKPOINTER
I
t
I
TIMING BELTDBIVE PULLEYClean.I
2. Set the camshaft pulley to TDC. Align the TDCmarks on the camshaft pulley to the cylinder headsurface.

3. Install the timing belt tightly in the sequence shown'
OTiming belt drive pullev (crankshaft) )@Adjusting
pulley -towater pump pulley J@Camshatt pulley'
NOTE: Make sure the timing belt drive pulley and
camshaft PulleY are at TDC
7.
Loosen and retighten the adiusting bolt to tension
the timing belt.
lnstall the lower cover and upper cover.
NOTE: Clean the upper and lower covers before
installation.
lnstall the crankshaft pulley, then tighten the pulley
bolt (see page &16)
Rotate the crankshaft pulley about five or six turns
counterclockwise so that the timing belt positions
on the Pulleys.
Adjust the timing belt tension (see page 6-18).8.
L
9. Check that the crankshaft pulley and camshaft pul-
ley are both at TDC.
CRANKSHAFT PULLEY:
CAMSHAFT PULLEY:
lf the camshaft and crankshaft pulleys are not posi-
tioned at TDC, remove the timing belt and adjust
the position following the procedure on page 6-20'
Then reinstall the timing belt.
After installation, adjust the tension of each belt
. See section 23 for alternator belt tension adjust-
ment.
a See section 22 tot NC compressor belt tension
adjustment.
. See section 17 for P/S pump belt tension adjust
ment,
(wHrTE)
"UP" MARK
TDC MARK
11.
6-21

Cylinder Head
4. Apply liquid gasket (Part No. 08718 - 0001 or 08718 -
0003) to the head mating surfaces of the No. 1 and
No.5 camshaft holders.- Apply liquid gasket to the shaded areas
Set the rocker arm assemblY in place and loosely
installthe bolts.- Make sure that the rocker arms are properly posi-
tioned on the valve stems.
Tighten each bolt two turns at a time in the sequence
shown below to ensure that the rockers do not bind
on the valves.
Specitied torquo:
8 mm bolts: 20 N.m (2.0 kgt'm, l/t lbf'ft)
Apply engine oil to the threads.
6 mm bolts: 12 N.m {1.2 kgif'm, 8.7 lbf'ft)
Apply engine oil to the thresds.
6 mm bolts: O, @. @, @
7. Install the back cover. then install the camshaft pul-!
6-45
lnstallation
lnstallthe cylinder head in the reverse order of removal:
NOTE:
. Always use a new head gasket.
. Cylinder head and cylinder block surface must be
clean.
. "UP" mark on the camshaft pulley should be at the top
. Turn the crankshaft so the No. 1 piston is at TDC (see
page 6-20).
. Clean the oil control orifice before installing.
a Do not use the upper cover and lower cover to store
removeo rlems.
Clean the upper cover and lower cover before instal-
taUon.
Cylinder head dowel pins must be aligned.1.
CYUNOER HEAD
PINS
(cont'd)

Cylinder Head
Installation (cont'dl
Position the camshaft correctly (see page 6-20).
Tighten the cylinder head bolts sequentially in four
steps.
rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft|
2nd srep: O - @ 49 N.m (5.0 kgf.m, 36 tbtft)
3rd stop; O - @ 67 N.m {6.8 kgf.m, /r9 lbl'ft}
4th st6p: O, O 67 N.m 16.8 kgf.m, 49 tbf.ftl
NOTE:
. We recommend using a beam-type torque
wrench, When using a preset-type torque wrench.
be sure to tighten slowly and not to overtighten.
. If a bolt makesany noisewhileyou aretorquing it,
loosen the bolt, and retighten it from the 1st step,
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Install the intake manifold and tighten the nuts in a
crisscross pattern in two or three steps, beginning
with the inner nuts (see pages 9-2 thru 9-4).
. Always use a new intake manifold gasket.
Install the exhaust manifold and tighten the nuts in
a crisscross pattern in two or three steps, beginning
with the inner nut {see pages 9-6 and g-7).
. Always use a new exhaust manifold gasket.
Install the exhaust manifold bracket. lnstall the
exhaust pipe A and the bracket, then install the cover.
4.
6-46
\-
(
7.Installthe timing belt (see page 6-20).
Adjust the valve clearance (see page el2),
Install the head cover gasket in the groove of the
cylinder head cover, Seat the recesses for the
camshaft first, then work it into the groove around
the outside edges.
NOTE:
. Before installing the head cover gasket, thor-
oughly clean the seal and the groove.
. When installing, make sure the head cover gas-
ket is seated securely in the corners of the
recesses wath no gap.
COBNERS OFTHE RECESS
CORNERS OFTHE REcEss covEB
Apply liquid gasket to the head cover gasket at the
four corners of the recesses.
NOTE:
. Use liquid gasket, Pan No. 08718 - 0001 or 08718- 0003.
. Check that the mating surfaces are clean and dry
before applying liquid gasket.
. Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.
. After assembly, wait at least 30 minutes before
filling the engine with oil.
8.
9.
I
10.

Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
r 4).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
OOWEL BOLTS'10 x 1.25 mm
Remove the intermediate shaft from the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
'1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring.
2. Remove the intermediate shaft outer seal from theDeaflng suppon.
3. Remove the external circlip,

Front Seat Belt
Replacement
CAUTION: Check the front seat belts for damage, and
replace them it necessary. Be carolul not to damage
them during removal and installation.
Front seat belt removal (4Dl:
1.Slide the front seat forward fully.
Remove the center pillar lower trim panel (see page
20-59).
Remove the upper anchor cover and lower anchor
cap.
SHOULDERANCHOR
UPPER ANCHOR BOLT7/16-20 UNF32 N.m (3.3 kgit m,24 lbf.ft)Apply liquid thread lock.
2.
3.
FRONT SEATBELT
RETRACTOR
RETRACTORMOUNTING BOLT6x1.0mm9.8Nm(1.0kgf.m.7.2 tbf.ftl
ER ANCHOR
Remove all the anchor bolts and the retractor bolt,
remove the retractor mounting bolt, then remove
the front seat belt and retractor.
1
I
ILOWCAP
7/1&20 UNF32 N.m (3.3 kgl.m.24 rbl.ftl
7/16-20 UNF32 N.m {3.3 kgf.m,24lbf.ft}
6.
8 x 1.25 mm23 N.m {2.3 kgt'm,17 tbf.ft)
ANCHORADJUSTER
7. Installation is the reverse of the removal procedure
NOTE:
. Check that the retractor locking mechanism func-
tions as described on page 20-91.
. Make sure you assemble the washers and collars
on the uDDer and lower anchor bolts as shown.
. Before installing the anchor bolts, make sure there
are no twists or kinks in the front seat belt.
Upper anchor boh construciion:
UPPER ANCHORBOLT
Remove the center pillar upper trim (see page 20-59)
Remove the shoulder anchor adjuster.
UPPER
COLLARApply liquid thread
(cont'd)
20-85
SUSHING

Front Seat Belt
Replacement (cont'dl
Lower anchor bolt construction:
SPRINGWASHER
COLLARSBUSHINGLOWERANCHOB
Retractor bolt construqtion :
TOOTHEDLocK W\HER
)rtnl
tv-
RETRACTORBOLT
I
llo1r",ffi)
\y
-"\s\,/
IRETBACTOF
LOWER ANCHOR
WASHEBS
\
20-86
Front seat belt removal (2Dl3Dl:
1. Sljde the front seat forward fully.
2. Removel
. Rear seat-back and rear seat cushion (see pages
20-80, 81)
. Rear center shelf and rear side shelf (3D. see
page 20'60)
. Rear trim panel (3D, see page 20-60)
. Side trim panel (see pages 20'60,61)
3. Remove the upper anchor cover and lower anchor cap.
UPPER ANCHOR BOLT7/16-20 UNF32 N.m (3.3 kgI.m,24 tbf.ftl
@<-'-.-.-.- ,PPER aNcHoR
RETRACTORMOUNTING BOLT6x1.0mm9.8 N.m (1.0 kgt m,7.2 tbtft)
LOWER ANCHOR BOLT7/16-20 UNF32 N.m (3.3 kgl m, 24lbtft)
LOWEBANCHORCAP
IIto
4. Remove all the anchor bolts and the retractor bolt,
remove the retractor mounting bolt, then remove the
front seat belt and retractor.
RETRACTOR BOLT7/16-20 UNF32 N m 13.3 kgf m,24 tbf.ftl

Rear Seat Belt
Replacement
CAUTION: Chack the rear seat belts for damage, and
replace them if necessary, 8e carolul not to damage
lhem during removal and installation.
Rear seat belt removal {2Dl4D}:
1. Remove:
. Rear seat cushion (see pages 20-79, 81)
. Rear seat-back (2D, see page 20-81)
. Side trim panel (2D, see page 20-61)
. Rear shelf (see pages 20-59,61)
. Rear trim panel {see page 20-62}
. Trunk side trim, Japan-produced (see page 20-62)
. Trunk trim panel, USA-produced (see page 20-62)
2. Remove all the anchor bolts and retractor bolt, then
remove the rear seat belt and retractor.
UPPER ANCHOR BOLT7/16-20 UNF32 N.m (3.3 kgf.m,2,1 lbtft)
RETNACTOR BOLT7/1F20 UNF32 N.m {3.3 kgf.m,24 tbt.ft)
7/16-20 UNF32 N.m {3.3 kgf.m,24lbt.ft)
20-88
R€TRACTOB
3. Installation is the reverse of the removal procedure.
NOTE:
. Check that the retractor locking mechanism func-
tions as described on page 20-91.
. lvlake sure you assemble the washers and collar
on the upper anchor bolt as shown.
. Before installing the anchor bolt. make sure there
are no twists or kinks in the rear seat belt.
Upper anchor boh condruqtion:
SPRINGWASHER
Lower anchor bolt construction:
LOWER ANCXOREOLT
LOWER ANCHOR
Retractor bolt construction:
RETRACTORBOLT
t7 /7--^,l/rn .----. A -nrfi|lH \
tr\7-\
/\TOOTHEDLOCK WASHER