head bolt HONDA CIVIC 1996 6.G Workshop Manual

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 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

VTEC Rocker Arms
Inspection Using Special Tools (D16Y8 enginel
CAUTION:
o Before using the Valve Inspection Tool. mak6 surethat the air pressure gauge on the air comprsssor
indicates ovor 400 kPa {4 kgf/cm,, 57 psil.
. Inspect th6 valve clearanco before rockar arm inspec-
tion.
. Cov€r th€ timing belt with a shop towel to protect
the bolt.
. Check tho intake prima.y rockff arm of each cylindel
at TDC.
1.Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylinder
neao cover,
Plug the relief hole with the specialtool.
OTLAJ - PR3O2OB
I,^ A IAo- tu
3. Remove the sealing bolt from the inspection hole
ancl connect an air pressure regulator with a 0 - 100psi gauge.
l0 x 1.0 mmSEALING EOLT20 N.m (2.0 kgf.m, 14 lbf.ft)
(AIR PRESSUREREGULATOR
{Commerciallyavailable). Pullthe dialandturn to adjust,

Valve Clearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylindsrhead temperature is less than 100"F (38"C).
. After adjusting, retorque the crankshaft pulley bolt(see page 6-16).
1, Remove the cylinder head cover.
NOTE; Refer to page e46 when installing the cytinderhead cover.
2. Remove the upper cover (see page 6-19).
3. Set the No. 1 piston at TDC. The "UP" mark on the
cam-shaft pulley should be at top, and the TDC
marks should align with the cylinder head surface.
TDC MARKS
4. Adjust valves on No, 1 cylinder.
Intako: 0.18 - 0.22 mm {0.007 - 0.009 in}
Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inl
"UP" MARK
6-12
No.4
5. Loosen the locknut, and turn the adjustment screwuntil the feeler gauge slides back and forth with asliOht amount of drag,
D16Y7 engin.:
CAUTION: Do not oyertighlen the locknuts; thorockor arms are made of aluminum.
INTAKE end EXHAUST VALVELOCKNUTS
Dl6Y5, Dl6Y8 engin€3:
INTAKE .nd EXHAUST VALVELOCKNUTS20 N.m 12.0 kstm, 14lbtft)
Adiusting screw locations:
IMTAKEo.4 1{o. 3 No. 2
tr'
(
nb.3 No.2 No. 1EXHAUST
18 N.m (1.8 kgI.m, 13 tbl.ftl

Valve Seals
Replacement (Cylinder head removal not requiredl
NOTE: Cylinder head removal is not required in thisprocedure.
The procedure shown below applies when using the in-
car valve spring compressor (Snap-on YA884S withY48845 - 2 A7/8" attachment).
!@@ Alway wear approved eye protection whenusing ihe in-cai valve spring compressor.
1. Turn the crankshaft so that the No. I and the No. 4pistons are at top dead center (TDC).
2. Remove the cylinder head cover and the rocker arm
assembly.
NOTE:
. Refer to page 6-30 for rocker arm assembly
removat.
. When removing or installing the rocker armassembly, do not remove the camshaft holder
bolts. The bolts will keep the holders, springs
and rocker arms on the shaft.
. Refer to page 6-46 when installing the cylinder
head cover.
Remove the fuel injectors and the wire harness.
Using the 8 mm bolts supplied with the tool. mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit over the cam-
shaft as shown.
lnsert the cross shaft through the top hole of thetwo uprights.
3.
4.
6-14
Intake Valve Seals:
6. Select the 7/8 in diameter short compressor attach-ment, and fasten the attachment to the No. 4 hole of
the leve. arm with the speed pin supplied.
8.
7.lnsert an air adapto. into the spark plug hole. pump
air into the cylinder to keep the valve closed whilecompressing springs and removing the valve keepers.
Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
neao.
OIL PASSAGES
Position the lever arm under the cross shaft so thelever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for thespring being compressed. Use the front position
slot on the lever as shown.
,
I
i'
OIL PASSAGES
IN-CAR SPRING COMPRESSOR
SLOT

Crankshaft Pulley and Pulley Bolt
Replacement
When installing and tightening the pulley. follow theprocedure below,
Clean, remove any oil, and lubricate points shown
below.
O: Clean
x: Bemove any oil
a: Lubricate
TIMING BELTGUIOE PLATE
Crankhaft pulley bolt size and torque value:
14 x 1.25 mm
20 N.m {2.0 kgl.m, 14 lbf.ft) + 90'
NOTE: Do not use an impact wrench when installing.
HOI.I'ER HANDTI07JAB - 001020A
HOLDER ATTACHMENT. 50 mm07NAB - ootoilllA
S(rc(ET, 17 mm07JAA-lxtl010A or{Co.nm.rci.lly .v.il.bl.}
CRANKSHAFT
6-16
'1.Tighten the pulley bolt to the specified torque.
Torque: 20 N.m {2.0 kgf.m, 14 lbf'ft}
Use I felt tip pen to mark the pulley bolt head andwasher.
EMBOSSING MARKS
3. Tighten the pulley bolt an additional 90".
EMBOSSING MABKMARKING
\
MARKING
MARKING
I

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
Inspection
1.
2.
3.
Remove the cylinder head cover.
. Refer to page 6 46 when installing.
Remove the upper cover (see page 6 19).
Inspect the timing belt for cracks and oil or coolantsoakrng.
NOTE:
. Replace the belt if oil or coolant soaKeo.. Remove any oil or solvent that gets on the belt.
Rotate pulleyand inspect belt.
After inspecting, retorque the crankshaft pullev bolt{see page 6- 16).
o- I6
Tension Adjustment
CAUTION: lt*ays aa;j"t the timing bett rension withthe engine cold.
NOTE:
. The tensioner is spring loaded to apply tension to thebelt automatically after making the following adjustment.
. Always rotate the crankshaft counterclockwise whenviewed from the pulley side. Rotating it clockwisemay result in improper adjustment of the belt ten-sion.
. lnspect the timing belt before adjusting the belt ten-ston.
1.Remove the cylinder head cover.
. Refer to page 6,46 when installing.
Remove the upper cover (see page 6,'19).
Rotate the crankshaft five or six revolutions to setthe belt.
Set the No. 'l piston at TDC (see page 6-21).
Loosen the adjusting bolt 180'.
2.
3.
4.
5.
\I
ADJUSTING BOLT44 N.m {4.5 kgt m,33 rbf.ft)
7.
8.
Rotate the crankshaft counterclockwise three teethon the camshaft pulley.
Tighten the adjusting bolt.
After inspecting, retorque the crankshaft pulley bolt(see page 6-16).

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.