Bearing cap install HONDA CIVIC 1996 6.G Workshop Manual

Section 7
Unlt of length: rnm ( n)
Engine Block(816A2 engine) -
MEASUREMENT
Warpage of deck surface
Bore diameterBore taperReboring limit
STANOARD {NEW)
0.05 (0.002)
8L00 81.02 (3.189 3.190)
SERVICE LIMIT
0.08 {0.03)81.07 (3.192)
0.05 (0.002)
0.25 (0.01)
Cylinder block
PistonSkin O D. At 15 mm (0.6 in)
{rom bottom of skirt
Clearance in cylinder
Groove width (for ring) ToPSecondoil
80.980 - 80.990 (3.lUUz 3. rUubl du Y/u lJ. ro/o,
I0.010 0.040 (o.ooo4 - 0.0016' 0 05 r0 002) II O3O 1.040 10.0406 - 0.04091 1 060 {0 0417) |1.230 - 1.?40 {0.0484 . 0.04881 1.260 10.04961 1'*: ?:::i?l:91'::ll:l I::::::= lPiston ringRing-to-groove clearance
Ring end gap
o.D.Pin to-piston clearance
Pin'to rod interference
Small end bore diameter
Large end bore diameterEnd play installed on crankshaft
Main journal diameterNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod journal diameterTaperOut of roundEnd play
Total runout
Main bearing to_journal oil clearance
No. 1, 2, 4 and 5 journals
No. 3 journal
Bod bearing'to iournal oil clearance
Second
Top
Secondoil
Nominal
0.13 (0.005)
0.1310.005)0.60 (0.024)
0.60 t0.024)0.7010.028)0.70 (0.028)
,rr]q!4l
-l
u.u45 - u.u/u lu.uu ro
0.040 - 0.065 (0.0016 0.0026)*l
0.045 - 0.070 (0.0018 0.0028)*'
0.20 - 0.35 (0.008 - 0.014)*1
o.20 - 0.30 (0.008 - 0.012)*'
0.40 0.55 (0.016 0.022)
0.20 - 0.50 (0.008 - 0.020)*'
0.20 - 0.45 (0.008 - 0.018)"
20.994 - 21.000 {0.8265 - 0.8268)
0.010 - 0.022 (0.0004 0.0009)
0.013 - 0.032 (0.0005 - 0.0013)
20.968 20.981 (0.8255 - 0.8260)
lliSlto?,o.oou o.o''r, o.rotoo'ut
Piston pin
Connecting rod
54.976 55.000 (2.1644 - 2.1654)
54.970 - 54.994 (2.1642 2.1651)
44.976 - 45.00011.'1707 - 1.1711|
0.005 (0.0002) max.0.004 (0.0002) max.0.10 0.35 (0.004 - 0.014)
0.020 (0.0008imax.
0.010 (0.0004)
0.006 (0.0002)
0.45 (0.018)
0.030 (0.0012)
Crankshaft
Eearing0.024 - 0.042 (0.0009 0.0017)
o.o3o - 0.048 {0.0012 0.0019)
0.032 - 0.050 (0.0013 - 0.0020)
0.06 (0.002)
0.06 (0.002)
0.06 (0.002)
*1: RIKEN manutactured prston rrng*2:TEIKOKU PISTON RING manufactured piston ring
gineslSection 8
(cont'd)
Engine Lubri,cation (Dl6Y5, Dl5Y7' Dl6Y8 enginesl -
MEASUREMENTSTANOARD (NEW) S€RVICE LIMIT
4.3 (4.5, 3.8)Ior engine overhaul
3.6 (3.8, 3.2) for oil change, including filter
3.3 (3.5, 2.9) for oil change, without filter
3.7 (3.9,3.3)for engine overhaul
3.3 (3.5, 2.9) for oil change, including filter
3.0 {3.2, 2.6} for oil change, without filter
0.02 - 0.14 (O.OO1 - 0.006) 0.20 {0 008)
0.10 0.18 (o.oo4 - 0.007) i 0.20 (0 008)
o 03 !.08 (qool!.oo3l _ (0 006) -
70 (0.7, 10) min.
340 (3.5,50) min
Engine oilCapacity | (US qt, lmp qt) D16Y7
D16Y5 D16Y8
lnner-to-outer rotor radial clearance
Pump housing to_outer rotor radialclearance
Pumo housrnq_to rotor a)rial clearance
Pressure setting with oil temperature 176'F (80'Ci
kPa (kgf/cm', PsiI at idleat 3,000 rpm
Oil pump
Relief valve
3-5

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#*

lllustrated Index
(cont'dl
I Luoricate att internal parts with engine oil during reassembly.
NOTE:
' Apply liquid gasket to the mating surfaces ofthe rightside coverand oil pumpcase before installingthem.. Use liquid gasket, part No. 08718 - 0001 or 087,18 _ OOO3.. Clean the oil pan gasket mating surfaces before installing it.
D16Y7 engine:6 x 1.0 mm12 N.m (1.2 kgt.m.8.7 tbf.tr)DRAIN BOLT44 N.m {4.5 kgt.m.33 tbt.ttl
,(
I
I
OIL PAN GASKETFLYWHEEL COVERIM/T)6x 1.0 mm12 N.m ('l .2 kgt.m, 8.7 tbt.trl
OIL PANRefer to page 7-27
Apply liquid gasker tothese points.
Replace.
WASHERReplace.12 x '1.0 mm118 N.m{12.0 kgt.m, 87 tbf.tr}
11 x 1.5 mm51 N.m15.2 kgl.m,38lbtftl
Apply engine oilto the boltthreads.NOTE: After torquingeach cap, turn the crankshaftto check for binding.
MAIN BEARINGSSelection, page 7-10
MAIN BEARING CAP
CRANKSHAFTInstallation, page 7 23
NOTE: New main bearings mustbe selected by matching crankand block identification markings.
6 r 1.0 mm11 N.m {1.1
6 x 1.0 mm11 N.m 11.1
ksI.m, 8 lbt.ft)
OIL SCREEN
kgt.m, 8 lbf.trl
Check for cracks.
CRANKSHAFT OIL SEALInstallation,pages 1 22 a^d 7-29
\:eprace'
GASKETReplace.
6 x 1.O mm11 N.m {1.1 kgt.m,8 rbt.frl
RIGHT SIDE COVERApply liquid gasker1o matrng surface,
OIL PUMPOverhaul, page 8-12Bemoval/lnspection,page 8-13
DOWEL PIN
WASHERSGrooved sides face outward.NOTE: Thrust washer thicknessis fixed and must not be changedby grinding or shimming.
CRANKSHAFT SEAL
l.j"Ji:l"^ pages z.2e --.S)
Replace.
6 x 1.0 mm11 N.m {1.18 tbt.fr)
7-4
BREATHING PORT COVERMOUNT BOLTS6 x 1.0 mm11 N.m {1.1 kgt.m, 8 tbf.fr}Apply liquid gasker tothe boh threads.
DOWEL PIN

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

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

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)
\
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.

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
\
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)

6. Remove the bolts and the bearing caps.
CAUTION: To prevenl warpago unscrow lhe bolts
in s€quence 1/3 turn at a tims, r€paat the soquence
until all bolts ar€ loo3ened.
MAIN BEARING CAP BOLTS LOOSENING SEOUENCE
Remove the rod caps/bearings and main capvbear-
ings. Keep all caps/bearing in order.
Lift the crankshaft out of the engine, being careful
not to damage journals.
7.
S:_]ILOJLOAO
CRANKSHAFT14.
7-13
qRemove the upper bearing halves from the connect-
ing rods and set them aside with their respective
caos.
Reinstall the main caps and bearings on the engine
in proper order,
lf you can feel ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge
reamer. Follow the reamer manufacturer's instruc-
I|ons.
CAUTION; lf the ridge is not removed, it may dam-
age tho pistons as they are pushod out.
RIOGE REAMER
10.
11.
12.Use the wooden handle of a hammer to drive the
pastons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
Mark each piston/connecting rod assembly with its
cylinder number to avoid mixup on reassembly.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.

Connecting RodsPiston Pins
Selection
Each rod falls into one of four tolerance ranges {from O to+ 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)increments) depending on the size of its big end bore. lt,sthen stamped with a number {1, 2,3, or 4) indicating therange.
You may find any combination ot l, 2, 3, or 4 in any
engrne.
Normal Eore Size: 48.0 mm (1.89 in)
NOTE:
o Reference numbers are for big end bore size and doNOT indicate the position of the rod in the engine.. Inspect connecting rod for cracks and heat damage.
CONNECTING ROD AOREREFERENCE NUMBERHalf of number is stamped onbearing cap, the other half onconnectrng rod.
7-18
Installation
1. Use a hydraulic press for installation.
. When pressing the pin in or out, be sure you posi
tion the recessed flat on the piston against the lugson the base attachment.
816A2 engine
The arrow must face thetiming belt side of theeng Ine.
The mark must facethe timing belt sideof the engine.
D16Y5, D16Y7, O16Y8 engines
The arrow must face thetiming belt side o{ theengine and the connectingrod oil hole must face therear of the engine.
Adjust the length of thepiston pin driver to53 mm (2.09 4n)
PISTON PIN DRIVER SHAFT07973-PEOo3r0
PISTON PIN DRIVER HEAD
il--Z
P,"roNPrN
PILOT COLLAR07973-PE00200
PISTON PIN BASE INSERT07973 PEO0400
PISTON EASE HEAO07973 -5800100
,(
a

PistonsGrankshaft
lnstallation
Before installing the pistons, apply a coat of
engine oil to the ring grooves and cylinder
bores.
lf the crankshaft is already installed:
. Set the crankshaft to BDC for each cylinder.
. Remove the connecting rod caps, and slip short
sections of rubber hose over the threaded ends
of the connecting rod bolts.
. lnstall the ring compressor. check that the bear-
ing is securely in place, then position the piston
in the cylinder, and tap it in using the wooden
handle of a hammer.
o Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal align-
ment before pushing the piston into place
. Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torque the nuts to:
815A2 engine:
40 N.m {,1.1 kgf.m, 30 lbf'ft|
D16Y5, D16Y7, D16Y8 engines:
31 N.m (3.2 kgf'm,23 lbf'ft)
lf the crankshaft is not installed:
. Remove the rod caps and bearings, install the ring
compressor, then position the piston in the cylin-
der, and tap it in using the wooden handle of a
hammer.
. Position all Distons at top dead center.
1.
2.
The arrcw must facethe taming belt sideof the engine.
CONNECTING ROOOIL HOLE lD16Y5, D16Y7, D16YB ongines)
NOTE: Maintain downward force on the ring com-
pressor to prevent the rings from expanding before
entering the cylinder bore.
RUBBER
,lll
lnstallation
Before installing the crankshaft, apply a coat of
engine oil to the main bearings and rod bearings.
Insert the bearing halves into the cylinder block and
connecting rods.
Hold the crankshaft so the rod journals for cylinders
No.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rod
journals into connecting rods No. 2 and No. 3, and
install the rod caps and nuts finger-tight.
1.
2.
3.
5.
Grooved sides faceoulward.Botate the crankshaft clockwise, seat journals into
connecting rods No, 1 and No.4, and install the rod
caps and nuts finger-tight.
NOTE: Install caps so the bearing recess is on the
same side as the recess in the rod.
Check rod bearing clearance with plastigage (see
page 7-11), then torque the capnuts. Apply engine
oil to the bolt threads.
Torque:
816A2 sngine:/l{, N.m {a.l kgf.m, 30 lbf'ftl
D16Y5, D16Y7, Dl6Y8 engines:
31 N.m (3.2 kgf.m, 23 lbf'ft|
NOTE: Reference numbers on connecting rod are
for big-end bore tolerance and do not indicate the
position of piston in the engine.
Line up the marks wheninstalling the connectrng rod
cap.
6. Install the thrust washers on the No. 4 journal. Oil(cont'd)
7-23
the thrust washer surfaces,