check oil HONDA CIVIC 1996 6.G Workshop Manual

Standards and ServiceLimits
Section '14Automatic Transmission (cont'd)
UO
MEASUREMENTSTANDARD {NEW}
Wire Dia.o.D.Free LongthNo. ol CoilsHegulator valve spring ARegulato. valve spring BStator reaction springModulator valve springTorque convener check valve springCooler relief valve springRelief valve spring2nd oritice control valve spring1-2 shift valve spring2-3 sh ift valve spring3 4 shift valve spring'l st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd acc!mulator spring B2nd accumulator spring CLock up shift valve springLock up timing valve springLock-up control valve spring3 4 ofifice control valve springServo control valve springCPC valve springCPB valve spring4th exhaust valve spring
Springs1.8 {0.071)1.8 {0.071)4.5 \O.117)1.4 (0.055)
1.0 10.039)1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.035)
2.1 (0.083)
2.3 (0.091)
2.610.102)2.4 (0.094)
2.8 (0.'110)
1.6 (0.063)
2.2 (0.087)
2.2 t0.041)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.7 (0.028)
1.0 (0.039)
0.6 (0.024)
0.9 {0.035)0.9 (0.035)
14.7 (0.584)
9.6 (0.381)
3s.4 (1.407)
9.4 (0.374)8.4 (0.334)
8.4 (0.334)
8.6 {0.342)6.6 (0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)16.0 (0.636)10.2lo.402l17.0 {0.676)29.0 (1.152)
17.5 (0.6951
9.0 (0.358)
31.0 (1.220)
14.5 {0.576)7.6 (0.302)
8.1 (0.319)
6.610.262)6.6 (0.262)
8.1 (0.322)
5.6 (0.2231
8.1 10.322)6.1 10.242)
87.8 (3.457)
44.0 i.732l'30.3 (1.193)
35.0 {1.378)33.8 (1.331)
33.8 (1.331)
37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57.0 (2.2441
51 .0 \2.244189.1 {3.508)51.6 (2.031)
87.0 (3.425)
39.011.535)89.3 (3.516)
20.7 (0.815)
35.1 11.382)68.012.671173.7 12.902)80.7 (3.177)38.0 {1.496)37.5 fi.476)52.1 (2.051)
12.2 (0.480)
47.2 {1.858}36.4 {1.433)
16.511.01.910.94.24.213.422.016.326.826.a16.213.814.22.915.66.12.413.932.045.814.124.620.4
18.319.5
CVTSection 14
3-14
MEASUREMENTSTANDARD INEWISERVICE LIMITTransmissionfluidCapacity f {US qt, lmp. qt)6.4 {6.8, 5.6) for overhaul3.9 (4.1, 3.4) for fluid change
Hydraulicpressure
1kgflcm,, psi)
Forward clutch pressure at 1,500 rpm in E position1.4 - 1.15 114.3 - 11.A,203 - 2531Reverse brake pressure at 1,500 rpm in E position1.4 - 1.75 (14.3 11.8,203 2531Dr;ve pulley pressure at 1,500 rpm in E posrtrono.2 -0.7 12.0 -7.1,28- 1011Driven pulley pressure at 1,500 rpm in N positionr.5 - 2.3 115.3 - 23.5, 218 - 334)Lubrication pressure at 3,000 rpm in E posrtronAbove 0.212,30)Stall speed fpm (Check with vehicle on level ground)
E position
E, E, El positions2,5003,0002,350 - 2,6502,800 - 3, r00ClutchClutch initial clearance Forward clutchStart clutchReverse brakeClutch return spring free length Forward clutchStart clutchReverse brakeClutch disc thickness Forward clutchStart clutchReverse brakeClutch plate thickness Forward clutchSta rt clutchReverse brake
0.6 - 0.8 (0.024 - 0.031)0.5 - 0.7 (0.020 0.028)0.45 - 0.75 (0.018 - 0.030)30.5 {1.201)40.9 (1.610)
29.4 (1.157)
1.88 - 2.00 (0.074- 0.079)1.88 2.00 (0.074 - 0.079)1.94 - 2.06 (0.076 - 0.081)1.95 - 2.05 (0.077 -0.081)
2.25 2.35 (0.089 - 0.093)1.90 - 2.00 (0.075 0.079)
,*x.ar}38.9 (1.531)
27.411.019l'Until grooves worn out
Until grooves worn outDiscolorationDiscolorationDiscoloration
L.

Engine Removal/lnstallation
Installation (cont'd)
Except CVT:
12 x 1.25 mm64 N.m (6.5 kgd.m,
Tighten the bolts/nut on the left front mount in thenumbered sequence shown {O - @).
(t 12 x 1.25 mm83 N'm (8.5 kgf.m,61 tbt.trl
/+4 N.m 14.5 kgf.m,33 lbt.trl
O 12 r 1.25 mm59 N.m 16.0 kgt.m,43 tbt.rtlSeplace.
5-16
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7. Perform the following:
. Clean the areas where the driveshaft(s) and theintermediate shaft contact the transmission (dif_ferential) thoroughly with solvent or carburetorcteaner, and dry with compressed air.. Check that the set rings on the ends of the drive_shaft and intermediate shaft click into place.CAUTION: Use new set rings,. Adjust the shift cable (see section 14).. Adjust the throttle cable (see section 11).. Adjust the cruise control cable (see section 23).. Refill the engine with engine oil (see page 8-6).. Refill the transmission with fluid (see section 13,14).
. Refill the radiator with engine coolant (see page10-7).
. Bleed air from the cooling system with the heatervalve open (see page j0-7).
. Clean the battery posts and cable terminals withsandpaper, assemble them, then apply grease toprevent corrosaon.. Inspect for fuel leakage (see section j l).After assembling the fuel line, turn on l) the igni_tion switch (do not operate the starter) so that thefuel pump runs for approximately two secondsand the fuel line pressurizes. Repeat this opera_taon two or three times, then check for fuel leak_age at any point in the fuel line,

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VTEC Control System
Troubleshooting Flowchart (cont'd)
VTEC PRESSURE SwlTCH 2PCONNECTOR
Wire side of female(€rmrnats
VTEC SOLENOID VALVE lPCONNECTOR
I r----'t I
ll ' ff---r'-'1
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Terminal side ofmale terminal
A/T LOW PRESSUREw/PAt{EL07406-0070300
NOTE: Keep measuring time as short aspossible because engine is running with noload (less than one minute).
PRESSURE GAUGEADAPTER07NAJ - P07010A
A/T PRESSURE I{OSE07406 - 0020201
ot
A/T PRESSURE HOSE.2,210 mm07MAJ - PY&llA andA/T PRESSURE ADAPTER07MAJ - PY,()120
6-4
(From page 6-3)
(To page 6-5)
Test the VTEC Pr6suro SwitchWiro:Nleasure voltage across the VTECpressure switch 2P connector.
. Rcpai. opon in tho wirebrtw.en VTEC pr6.urc switchand G101.. lf th. wir6 b OK, sub.thuto alnown-good ECM/PCM !ndracheck.
ls there baftery voltage?
Te3t the VTEC Solonoid V.lve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No. 1 andbody ground.
ls there 14 - 30 0?
Te3t tho WEC Solonoid Vatvo:'1. Remove the VTEC pressureswatch and install the specialtool as shown, then reinstallthe VTEC pressure switch.2. Reconnoct the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector.3, Connect the tachometer (seesection 11).4. Stan the engine.5, Warm up engine to normaloperating temperature (cool,ing fan comes on).6. Check oil pressure at enginespeeds D16Y5 engine: 1,000and 3.000 rpm, D16Y8 engine:1,000,3,000 and 5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,, 7 psi)?In.poct the VTEC aolonoid vllvols.c p.g. &6).
:(
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(From page 6'4)
Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Disconnect the wEC solenoidvalve 1P connector.3. Attach the battery positave
terminal to the VTEC solenoidvalve terminal.4. Start the engine and checkthe oil pressure at enginespeed of 5,000 rpm.
Inspect lhe VTEC solonoid valve
lsee p6ge m).ls the pressure above 390 kPa(4.0 kgtcm',57 psi)?
Test the VTEC Pressure Switch:With the battery positive terminalconnected to the VTEC solenoidvalve, measure voltage betweenthe ECM/PCM connector terminal'96 - 98: Cl5,'99 - 00: C10 andbody ground.
ls there battery voltage above5,000 rpm?
T6st the VTEC Solenoid Valvewire:1. Turn the ignition switch OFF.2. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal and theECM/PCM connector terminal'96 - 98: A8, '99 00r B'12.
Repair open in the wire betweenthe ECM/PCM ('96 - 98: A8, '99 -
0o: 8l2l and VTEC solenoid v.lv6connoc{or.
Test the VTEC Solenoid Valve
Check for continuity between theVTEC solenoid valve 1P connectorterminal €nd body ground.
ReDair 3hort in the wire betweenthe ECM/FCM ('96 - 98: A.8, '99 -
0O: Bl2l and VTEC aolenoid valveconnectot,
ls there continuity?
Substitute a known-good ECM/PCM and recheck. lf symptom/indication goes away, replacethe original ECM/PCM.
VTEC SOLENOID VALVE1P CONNECTOR
Terminalside ofmale terminal
ECM/PCM CONNECTOR C {31P}
'99 - 00:'96 - 98:
CONNECTOR
'99 - 00:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTORB {25Pt1P CONNECTOR'96 - 98:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTOR
A {32P1
VTS{GRN/YEL)
wire side o{ femaleterminals
wire side oI temaleterminals
VTM

VTEC Solenoid Valve
Inspection
1.
6x1.0mm12 N.m 11.2 kgf.m,8.7 lbtft)
Disconnect the 1P connector from the VTEC sole-noid valve.
Measure resistance between the terminal and bodyground.
Resistance: l4 - 30 O
lf the resistance is within specifications, remove theVTEC solenoid valve assembly from the cylinder
head, and check the VTEC solenoid valve filter for
cloggrng.
. lf there is clogging, replace the engine oil filterand the engine oil.
VTEC SOLENOID VAI-VE ASSEMBLY
6-6
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4. lf the filter is not clogged, push the VTEC solenoidvalve with your finger and check its movement.
. lf the VTEC solenoid valve is normal. check the
engane oil pressure.
6x1.0mm12 N.m {1.2 kgt.m,8.7lbf.ft)
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6, Remove the camshaft holders. then measure the
widest ponion of the plastigage on each journal.
Camshaft-to-Holder Oil Clearance:
Standard lNew):0.050 - 0.08!t mm
{0.002 - 0.004 in}
Service Limit : 0.15 mm {0.006 in)
lf the camshaft-to-holder oil clearance is out ot tol-
erance:- And the camshaft has already been replaced,
you must replace the cylinder head.
- lf the camshaft has not been replaced, first check
the total runout with the camshaft supported on
V-blocks.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 inl max.
Service Limit: 0.04 mm {0.(X)2 in)
-7.
Rotate camshattwhile measuring.
L
- lf the total runout of the camshaft is within toler-
ance, replace the cylinder head.
- lf the total runout is out of tolerance, replace the
camshaft and recheck the camshaft-to-holder oil
clearance. lf the oil clearance is still out of toler-
ance. replace the cylinder head.
INTAKEEXHAUST
O16Y/ engine35.299 (1.3897)37.281 (1.4678)
D16Y5
engrne
PRI38.427 11.5129138.784 (1.5269)
SEC32.193 (1.2674)
D l6Y8
engrne
PRI36.77811.44791
38.008 (1.4964)MID38.274 (1.5068)
sEu37.065 (1.4592)
8. Check the cam lobe height wear.
Cam lobe height standard (New)
t/g a* rN Ex
- D16Y5 engine
PRI; Primary cam lobe, SEC: Secondary cam lobe
MtD: Mid cam lobe. T/B: Timing belt
lN: Intake, EX: Exhaust
PRIsEcMIDSEC
rts
- Dl6YE ongine
Unit mm (in)
Check this area {or wear.
6-37

Valve Guides
lntake Valve Dimensions
A Standsrd lNewl: 29.9 - 30.1 mm
B Standard (New):
C Standald {Newl:
C Service Limit:
D Standard (New):
D Service Limit:
11.18 - 1.19 inl
117.42 - 117.72 mm
(4.523 - 4.635 inl
5.'18 - 5.49 mm
{0.2r57 - 0.2r61 in)
5.,[5 mm (0.21,16 in]
0.85 - 1.15 mm
(0.033 - 0.0'15 in)
0.65 mm (0.026 in)
Exhaust Valve Dimensions
A Standard lNew): 25.9 - 26.1 mm
B Standard {Newl:
C Standard {New):
C Service Limit:
D Standard {New):
D Service Limit:
(1.02 - 1.03 in)
114.60 - 114.90 mm
11.512 - 4.521in1
5.i[5 - 5.46 mm
10.21lt6 - 0.2150 inl
5.,12 mm 10.213'l in)
1.05 - 1.35 mm
{0.041 - 0.053 in)
0.95 mm {0.037 in}
Valve Movement
Measure the guide-to-stem clearance with a dial indi-
cator while rocking the stem in the direction of normal
thrust (wobble method).
lniake Valve Stem-to-Guide Clearance:
St8ndard lNew): 0.04 - 0.10 mm
10.002 - 0.004 in)
Service Limit: 0.16 mm 10.006 in)
Exhaust Valvs Stem-to-Guide Glearance:
Standard {New}: 0.10 - 0.16 mm
10.004 - 0.006 in)
Sorvice Limit 0.22 mm (0.009 in)
O/'-_)
. lf the measurement exceeds the service limit,
recheck using a new valve.
. lf the measurement is now within the service
limit, reassemble using a new valve.
. lf the measurement still exceeds the limit,
recheck using the alternate method below, then
replace the valve and guide, if necessary.
NOTE: An alternate method of checking guide to
stem clearance is to subtract the O.D. of the valve
stem, measured with a micrometer, from the l.D. of
the valve guide, measured with an inside
micrometer or ball gauge. Take the measurements
in three places along the valve stem and three
places inside the valve guide. The difference be-
tween the largest guide measurement and the
smallest stem measurement should not exceed the
service limit.
lntake Valve Stgm-to-Guidg clearance:
Standard {Newl: 0.02 - 0.05 mm
{0.001 - 0.002 in)
Ssrvico Limit 0.08 mm (0.003 in)
Exhaust Valvo Stem-to-Guide Clearance:
Standard {New): 0.05 - 0.OB mm
{0.002 - 0.003 in)
S€rvice Limit 0.11 mm (o'Ooil in)
Valve extended 10 mm out from seat.
6-39

Cylinder HeadValve Seats
Warpage
NOTE: lf the camshaft-to-holder oil clearances (see
page 6-36) are not within specification, the cylinder head
cannot be resurfaced.
lf the camshaft-to-holder oil clearances are within sDeci,
fications, check the cylinder head lor warpage.
lf warpage is less than 0.05 mm (0.002 in), cylin-
der head resurfacing is not required.
lf warpage is between 0.05 mm (0.002 in) and
0.2 mm {0.008 in), resurface the cylinder head.
Maximum resurface limit is 0,2 mm (0.008 in)
based on a height of 93 mm (3.66 in).
Measure along edges, and three ways across center.
Cylinder Head Height:
Standard {Newl: 92.95 - 93.05 mm
{3.659 - 3.66:} in)
6-40
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Reconditioning
'1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf the guides are worn (see page 6-39).
replace them (see page 6-41) belore cutting the
valve seats.
VALVE SEATCUTTER(Commercially available)
2.
?
4.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutter
and the lower edge of the seat with the 60' cutter.
Check the width of the seat and adjust accordingly.
Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard (N€w):
Intake: 0.85 - 1.15 mm 10.033 - 0.045 in)
Exhaust: 1.25 - 1.55 mm {0.049 - 0.061 in}
Sorvice Limit:
Intake: 1.6 mm (0.063 inl
Exhausl: 2.0 mm (0.079 in)
Seat Width
5. After resurfacing the seat, inspect for even valve
seatingr Apply Prussian Blue compound to the
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against
the seat several times.

Valves
Reaming
NOTE: For new valve guides only.
1. Coat both the reamer and valve guide with cufting
orl.
2. Rotate the reamer clockwise the full length of the
valve guide bore.
3. Continue to rotate the reamer clockwise while
removing it from the bore.
4. Thoroughly wash the guide in detergent and water
to remove any cutting residue.
5. Check the clearance with a valve (see page 6-391.
Verify that the valve slides in the valve guide with-
out exerting Pressure.
Turn reamer inclockwise direclionon ly.
REAMER, 5.5 mmO7HAH. PJ'O'IOB
I
REAMER
oa)o,
o
o
1.
lnstallation
Coat valve stems with engine oil. Insert the valves
in the valve guides.
NOTE: Make sure lhe valves move up and clown
smoothly.
lnstallthe spring seats on the cylinder head.
Install the valve seals using the valve guide seal
installer.
NOTE: Exhaust and intake valve seals are not inter-
changeable.
2.
3.
WHITESPRINGBLACKSPRING
INTAKE VALVE SEALEXHAUST VALVE SEAL
VALVE GUIDE SEALINSTALLERKD2899 (Commercially available)NOTE: Use small lD end of
P
(cont'd)
6-43

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
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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.
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10.