head HONDA CIVIC 1996 6.G Workshop Manual

(urbY5, ul6Y7, Dl6Yg enl
MEASUREMENT
Sines) -Section6 -
STANDARD INFWTCompression250 rpm and wide open throftlekPa {kgf/cm,, psi) NominalMinimumMaximum variationWarpageHeight
End play
Camshaft to-holder oil clearanceTotal runoutCam lobe height D16y7
D16Y5
D16Y8
INEXIN
EXIN
EX
Secondary
PrimaryMidSecondary
930 {9.5, 135)200 12 0 ?R\Cylinder head
92.95 - 93.05 {3.659 3.663)0.05 {0.002)
Camshaft0.05,0.15 (0.002 0.006)0.050 - 0.089 (0.002 _ o.oo4)0.03 (0.001)max.
35.299 (1.3897131.241 /.1.4678)38.427 (1.5129)32.193 11 .267 4l38.784 (1.5269)
36.778 (1.4479)
38.274 (1.5068)
37.065 .4592)38.008 (1.4964)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
=
Valve clearanca {Cold)
Valve stem O.D.
Stem-to guide clearance
width
Stem insta ed height
Free lengrh Dt6y7D16Y5
INEXINEXINEX
INEXINEX
INEXINEX
INEXINEX
D16Y8
t.D.
Installed height
0.18 - 0.22 10.007 - 0.009)0.23 0.27 (0.009 0.011)5.48 - 5.49 (0.2157 0.2161)5.45 - 5.46 {0.2146 _ 0.2150}0.02 - 0.05 (0.001 _ o.oo2)0.05-008lono2-nnn?l
5.45 (0.2146)
5.42 tO.213410.08 (0.003)
0.11 (0.004)
1.6 (0.063)
2.0 (0.079)
53.a9 \2.122|j$.a9 Q.122)
Valve seat0.85 - 1.15 (0.033 - 0.045)1.25 - 1.55 10.049 - 0.061i53.17 - 53.64 {2.093 _ 2.112)53.17 - 53.64 (2.093 _ 2.112)Valve spring57 .9 (2.2a)
56.5 \2.22157 .9 t2.29l58.0 (2.2a)
58.7 {2.31iValve guide5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 _ 0.218)17.85 - 18.35 \0.103 - 0.722)18.65 19. t5 (0.734 _ 0.754)
5.55 t0.219)5.5s {0.219)
Rocker armArm-to shaft clearanceINEX0.017 - 0.050 (0.0007 0.0020)0.018 - 0.054 (0.0007 - 0.0021)0.08 (0.003)
0.08 (0.003)
Standards and Service Limits
Cylinder Head/Valve Train (Dt6y5, Dt6y7, D
L,
ra
3-2
LO

Unit of iength: mm (!n)
930 (9.5, 135)20012.0,zal
0.05 - 0.15 (0.002 - 0.006)
0.050 - 0.089 (0.002 - 0.004)
0.0310.001)max.33.088 (1.3027i
36.261 {1.4278)34.978 (1.3771)
32.785 {1.2907)35.720 (1.4063)
34.691 (1.3658)
u*u lo.r,ool5.420 (0.2134)
0.08 (0.003)
0.11 (0.004)
2.0 (0.08)
2.0 (0.08)
38.185 (1.5033)
37.885 (1.4915)
250 rpm (min riand Nominal
wide open throttle Minimum
kPa (kqf/cm', psi) Maximum variation
End play
Camshaft-to holder oil clea€nce
Total runoutCam lobe height lN PrimaryMidSecondaryEX PrimaryMidSecondary
0.15 - 0.19 (0.006 - 0.007)*
0.17 - 0.21 (0.007 - 0.008)*
5.475 - 5.485 10.2156 - 0.2159)
5.450 - 5.460 (0.2146 - 0.2150)
0.025 - 0.055 (0.0010 0.0022)
0.050-0.080 (0.0020 - 0.0031)
Valve clearance
Valve stem O.D.
Stem-to-guide clearance
INEXINEXINEX
1.25 - 1.55 {0.049 - 0.061)r.25 - 1.55 (0.049 - 0.061)
37.465 - 37.935 (1.4750 - 1.4935)
37.165 - 37.635 (1.4632 - 1.4817)
INEXINEX
width
Stem installed height
40.92 (1.611)*'
40.91 (1.6111"
36.71 (1.415)
41.96 (1.652)*r
4 r.94 (1.651)*'
free t*gth lN OUTER
5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 - 0.218i12.55 - 13.05 (0.494 0.5'j4)
12.55 - 13.05 (0.494 - 0.514)
LD. lNEX
Installed height lNEX
0.025 - 0.052 (0.0010 0.0020)
o.o2s - 0.052 {0.0010 0.0020)
Cylinder Head/Valve Train(816A2 engine) - Section
MEASUREMENTSTANDARD INEW)SERVICE LIMIT
*: Measuring point between camshaft and rocker arm'*1: NTHON H;TSUJO manufactured vatve spring. *2: CHUO HATSUJO manutactured valve spnng.
3-3

Unit of length: mm (in)
Fuel and Emission - Section
MEASUREMENTSTANOARO (NEW)
260 310 (2.7 - 3.2, 38 - 46)
260 - 310 (2.7 - 3.2, 38 - 46i
260 - 310 (2.7 - 3.2, 38 - 46)
210 - 320 Q.A - 3.3, 40 - 47 1
45 {11.9, 9.9)
M/T (neutral) I A/T or C\.T (lE or fd positioni
Fuel paessure
regulator
Pressure wilh fuel pressure regulator vacuum hose
disconnected kPa (kgvcm', Psi)D16Y5D 16Y7D16Y881642
FueltankCapacity I (US gal, lmp gal)
E ngineldle speed rpm
016Y5D16Y7D16Y8816A2
u.s.A.CanadaU,S,A.Canada
670 1 506701 50670150700 t 50
7501 507501 507501 50
700 t 50700 I 507001 50750150750 r 50
ldle CO %0.1 max.
Clutch - Serrtion 12
MEASUREMENTSTANDARD {NEWI I SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal play
Disengagement height to floorto carpet
16s (6 1/2)130 140 (5 1/8 5 1/2)
12 -21 t1l2 - 13/16183 (3 1/4)44 (1 3/4) min. Reference
FlywheelClutch surface ruoout
Rivet head depthThickness
0.05 (0.002) max.0.15 (0.006)
Clutch disc1.3- 1.9 (0.05 - 0.07)
8.5 - 9.1 (0.33 - 0.36)
0.2 {0.01)5.5 (0.22)
Pressure plateWarpageDiaphragm spring fingers alignment
0.03 (0.001) max0.6 (0.02) max
0.15 (0.006)
1.0 (0.04)
Lro
3-7
lfllHlllllllllrltllli[

ITEMMETRICENGLISHNOTESTEERINGSYSTEMTvpe P/sM/SOverall Ratio p/S
M/STurns, Lock-to Lock p/S
M/SSteering Wheel Dia.
Power assisted, rack and pinionRack and pinion1l.120.33.64..1380 mm 15.0 inSUSPENSIONTYPe Front and RearFront and RearIndependent double wishbone, coil springTelescopic, hydraulic nitrogen gas-filled
WHEELALIGN| 4ENTCamber FrontRearCaster F.ontTotalToe FrontRear
0.00,- 't'
1.40'ln 1 mm ln 1/16In 2 mm In 1/16EBAKE SYSTEMType FrontRea r
Pad Surface Area Front
Rea r
Parking Brake Type
Power assisted self adjusting ventilated discPower assisted self adiustjng solid discPower assisted sell adjusting dr!m37.5 cm'x 4 5.8 sq in x 4
44.1ctn,x4 ] 6.84sq-inxa
67.2 cmz x 4 | to.+ sq in ' I21.2 cm, x 4 3.3 sq in x 4Mechanical actuating, rear two wheelbrakes
5410 stamped onthe caliper body2056 stamped onthe caliper bodyDrumDisc
TIRESize and PressureSee lire intormation label
WASHERCapacity 2door Coupe/4,door Sedan
2,door Hatchback
2.5 f (2.6 LJS qt, 2.2 lmp qt)4.5 | (4.8 US qt,4.0lmp qt)2.51 (2.6 US qt, 2.2 lmp qt)4.5 f (4.8 US qt, 4.0 lmp qt)
USA modelCanada modelDXExcept DXELECTRICALBafteryStarterAlternatorFuses In Under dash Fuse/Felay BoxIn Under-hood Fuse/Belay 8oxIn Under hood ABS FLrse/Relay BoxHeadlightsFront Turn Signal/Parking LightsRear Turn Signal LaghtsBrake/TaillightsInner Taillights*,High Mount Brake LightBack up LightsLicense Plate LightsCeiling Light
Trunk LightsGauge LightsIndicator Lightslllumination and Pilot LightsHeater Control Panel Lights
12 V 38 AH/5 HR12 V 1.0 kW, 1.2 kW12V 75 A,80 A7.5 A, t0 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A, 80 A7.5 4.20 A, 40 A12V_60/55W12V -2115W
12V - 21W12V - 21/5W12V-5W12 V 18 W*" 21 W+" *3
12V 21W12v-5wl2V-8W(Withmoonroofl12 V - 5W (Without moonroof)
12V-1.4W,3W't2 v 1.12W. 1.4 W12v-0.84w, 1.4 W12V 1.4 W
Design Specifications
(cont'd)
P/S: Power Steering M/S: Manual Steering*l: 2-door Coupe *2: 2door Hatchback *3: 4-door Sedan*4: USA (HAM), Canada (HCM) produced *5: Japan produced
3-22
L'

Engine
Engine Removal/lnstallation ................ 5-1
Gylinder Head/Valve Train ................... 6-1
Engine Bfock .......... ...........7-1
Engine Lubrication ........... 8-1
Intake Manifold/Exhaust System ........ 9'1
Cooling ......... 10-1

Engine RemovaUlnstallation
Removal(cont'd)
38. Attach the chain hoist to the engine.
HOISTING BRACKETInstall on the cylinder headwitha8x1.25mmbolt.
5-10

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

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
(
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)
I
.(
I
\
;
..l'

VTEC Rocker Arms
2.
Manual Inspection (D16Y5 engine)
3.
1.
4.
Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Move the intake secondary rocker arm on the No. 'l
cylinder manually.
Check that the intake secondary rocker arm moves
independently of the primary intake rocker arm,
SECoNDARY PtROCKER ARM. Push and pull.
Check the intake secondary
cylinder at TDC.
rocker arm of each
a lf the intake secondary rocker arm does not move,
remove the primary and secondary intake rocker
arms as an assembly and check that the pistons in
the secondary and primary rocker arms move
smoothly.
a lf any rocker arm needs replacing, replace the pri-
mary and secondary rocker arms as an assembly.
PRIMARY ROCKER ARM
4.
Manual Inspection (D16YB engine)
1.Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Reter to page 6-46 when installing the cylin-
der head cover.
Push the intake mid rocker arm on the No. 1 cylin-
der manually.
Check that the intake mid rocker arm moves indepen-
dently of the primary and secondary intake rocker
arms.
MID ROCKERARM
Check the intake mid rocker arm of each cylinder at
TDC,
lf the intake mid rocker arm does not move.
remove the mid, primary and secondary intake
rocker arms as an assembly and check that the pis-
tons in the mid and primary rocker arms move
smoothly.
lf any rocker arm needs replacing, replace the
primary, mid, and secondary rocker arms as an
assemory.
5,
6-7

VTEC Rocker Arms
Inspection Using SpecialTools (Dl6Y5 enginel
CAUTION:
. Before using th6 Valve Inspection Tool, make 3ure
that ths air pressure gaugo on the air comptsssor
indicates over iloo kPa 14 kgf/cmr, 57 psi).
. Inspecl th6 valv€ clearance beforo rocker atm insDec"
tion,
'1.
Cover the timing belt with a shop towel to protect tho
belt.
Check ths intakg primaty rocker arm of each cylindqr atTDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Plug the relief hole with the special tool.
YY
OTLAJ - PR3O2OB
(
3, Remove the sealing bolt from the inspection holeand connect the an air pressure regulator with a 0 -
100 psi gauge.
10 x 1.0 mmSEALING BOLT20 N.m {2.0 kgj'm. 14lblft}
l
I
'10 x 1.0 mmADAPTER;NSp€CTTONHOLE (Commercially
available)
l'Pullthe dial andturn to adlust,
Loosen the regulator valve on the valve inspection
tool and apply the specified air pressure.
Spocified Air Pressurei
250 kPa {2.5 kg,t/cm,,36 psi}
o-at