bolt pattern HONDA CIVIC 1996 6.G Workshop Manual

Cylinder HeadRocker Arms
18.
19.
21.
22.
Removal (cont'd)
Remove the timing belt {see page 6-19).
Remove the camshaft pulley and back cover,
CAMSHAFTPULLEYClean when installing.
6x1.0mm8 x 1.25 mm37 N.m (3.8 kgf.m,21 tbtlrlApply engine oilto thebolt threads.
Remove the exhaust manifold {see pages 9-6 and 9_7).
Remove the intake manifold (see pages 9-2 thru 4).
Remove the cylinder head bolts, then remove thecylinder head.
CAUTION: To pr€vent warpage, unsclew lhe bohsin sequonce 1/3 turn at a time; rgpeat tho sequenceuntil all bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENGE:
6-30
Removal
1. Loosen the adjusting screws.
2. Unscrew the camshaft holder bolts, then,removethe rocker arm assembly.
NOTE:
a Unscrew the camshaft holder bolts two turns at at,me, in a crisscross pattern, to prevent damao_ing the valves or rocker arm assembly.. When removing the rocker arm assembly, do notremove the camshaft holder bolts. The bolts willkeep the camshaft holders, the springs and therocker arms on the shaft.
CAMSHAFT HOLDER BOLTS LOOSENINGSEOUENCE:
\(
ADJUSTING SCREWS

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.

I
Cylinder Head
Installation
lnstall the cylinder head in the reverse order of removal:
NOTE:
. Always use a new head and manifold gasket.. The cylinder head gasket is a metal gasket, Take carenot to bend it.
. Rotate the crankshaft, set the No. 1 piston at TDC (seepage 6-63).
. Do not use the middle cover and lower cover forstorang removed items.. Clean the middle cover and lower cover before instal_lation.
o Replace any washers that are damaged or deteriorated.
1. Install the cylinder head gasket, dowel pins and thehead oil control orifice on the cylinder head.
NOTE: Clean the oil control orifice when installing.
DOWEL PIN
6-84
2, Tighten the cylinder head bolts in two steps. In thefirst step, tighten all bolts in sequence to about 29N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten inthe same sequence to 83 N.m (8.S kgf.m,6t lbf.ft).
NOTE:
. Apply clean engine oil to the bolt threads andunder the bolt head.. We recommend using a beam-type torquewrench. When using a preset-type torque wrench,be sure to tighten slowly and not to overtighten.. lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLT TOROUE SEOUENCE
11x 1.5 mm83 N.m 18.5 kgf.m, 61 tbf.ftl
Install the intake manifold and tighten the nuts in acflsscross pattern in two or three steps, beginningwith the inner nuts.. Always use a new intake manifold gasket.
Install the exhaust manifold and tighten the newself-locking nuts in a crisscross pattern in two orthree steps. beginning with the inner nuts.. Always use a new exhaust manifold gasket.
4.

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

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

Flywheel
\Inspection
1.
2.
3.
Inspect the ring gear teeth for wear and damage
Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
Measure the flywheel runout using a dial indicator
through at least two full turns Push against the
flywheel each time you turn it to take up the
crankshaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (New): 0.05 mm (0.002 inl max.
Service Limit: 0.15 mm {0.006 in)
FLYWHEEL
OIAL INOICATOR
FLYWHEEL
lf the runout exceeds the service limit. replace the
flywheel.
Turn the inner race o{ the ball bearing with your tin-
ger. The ball bearing should turn smoothly and qui
etly. lf the inner race does not turn smoothly and
quietly, replace the bearing. Check that the ball
bearing outer race fits tightly in the flywheel. lf it is
loose. replace the ball bearing
IJ
4.
BALL BEARING tO
Replacement
1. Installthe special tool.
MOUNTINGBOLTS
RITIG GEAR HOLDER
oTLAB-PV00100oto7924-PD20003
2.Remove the flywheel mounting bolts in a crisscross
pattern in several steps as shown, and remove the
flywheel,
Remove the ball bearing from the flywheel
(cont'dl
12-9
FLYWHEEL
t\
m\J

FlywheelClutch Disc, Pressure Plate
Replacement (cont'dl
4. Drive the new ball bearing into the flywheel using
the special tools as shown.
DRIVER07749-0010000
ATTACHMENT,32x35mm07746-OOIOTOO
FLYWHEEL
BEARING
Align the hole in the flywheel with the crankshaft
dowel pin and install the flywheel. Install the
mounting bolts finger-ti9ht.
Install special tool, then torque the flywheel mount-
ing bolts in a crisscross pattern in several steps as
snown.
5.
6.
MOUNTING BOLTS118 N.m (12.0 kgl.m,87 tbf.ft)
RING GEAR HOLDER07LAB-PV00100ol07924 -PO20003
WVa// ,
12-10
Installation
1. Install the special tool.
Y
07936-3710r00
{P/N 08798-90021
RING GEAR HOLDER07LAB-PVOO100ot07924-PD20003
CLUTCH ALIGNMENT SHAFTOTJAF_PM7012A
2.
3.
Installthe clutch disc using the special tools.
Install the pressure plate.
RING GEAR HOLDERoTLAB PV00'l OO
07924 PD20003
OTJAF_PM70124HANOLE07936-3710100
CLUTCH DISC

Release Bearing
)
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten them in several steps to prevent
warping the diaPhragm sPring.
19 rbf.ft)
\
RING GEAR HOLDERoTLAB-PV00100ot07924-PD20003
CLUTCH ALIGNMENT SHAFT
OTJAF_PM7O12AHANOLE07936-3710100
MOUNTING BOLTS
8 x 1.25 mm
25 N.m (2.6 kgl'm.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
2. Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers
Remove the release bearing.
Check the release bearing for play by spinning it by
hand.
CAUTION: The releass bearing is packed with
grease. Do not wash it in solvent.
lf there is excessive play, replace the release bear-
ing with a new one.
RELEASE FORK
12-11

Transmission Housing
Removal
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the back-up light switch.
2. Remove transmission hanger.
TRANSMISSIONHANGER
BACK-UP LIGHT SWITCH
Remove the setting screws. washers. springs, and
steel balls.
STEEL BALLSO. 5/16 in
SPRINGL. 31.6 mm I 1.24 inl
13-12
SETTING SCREW
TRANSMISSION HOUSING
6.
4.Loosen the transmission housing attaching bolts in
a crisscross pattern in several steps, then remove
them.
Remove the 32 mm sealing bolt.
Expand the snap ring on the countershaft ball bear-
ing, and remove it from the groove using a pair of
snap ring pliers.
32 mm SEALING EOLT
Separate the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the thrust shim, oil guide plate. and oil gut-
ter plate from the transmission housing.
(o
7.
otLGUTTERTE
SNAP RING

I
Bearing RePlacement
NOTE: Check bearings for wear and rough rotation lf
the bearings are OK, removal is not necessary'
'1. Remove the ball bearings using a bearing puller as
shown.
EALL B€ARING
lnstall new ball bearings using the special tool as
shown.
NOTE: Drive the bearings squarely until they bot-
tom against the carrler.
DRIVER, 40 mm LD.?746 -0030100
\1,
Final Driven Gear RePlacement
1, Remove the bolts in a crisscross pattern in several
steps, then remove the final driven gear from the
ditferential carrier'
NOTE: The final driven gear bolts have left-hand
threads.
10 x 1.0 mm BOLT
1o1 N.m llO.3 kgf'm,74 5lbf'ft)
Lelt'hand threads
lnstall the final driven gear by tightening the bolts
in a crisscross pattern in several steps'