HONDA CIVIC 1997 6.G Owners Manual

Maintenance Schedule for 1999 Model
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4-22
Severe Conditions
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4-23

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

En g ine Removal/l nstallation
Removal "..'.'5'2
lnstaf lation '.' 5-12lgr"

Engine RemovaUlnstallation
Removal
@@
1.
. Make sure iacks and salety stands are placed ploperly
and hoist brackets are attached to the correct posi-
tions on the engine.
. Make sure the vehicle will not roll off stands and fall
while you are working under it.
CAUTION:
. Use fender covers to avoid damaging painted sur-face.
. Unplug the wilin9 connectors caretully while holdingthe conngstor portion to avoid damage,. Mark all wiring and hosos to avoid misconnoction.
Also, be sure that they do not contact other wiring or
hoses or interfere with other parts,
Secure the hood as open as possible.
Disconnect the battery negative terminal first. thenthe positive terminal. Remove the battery.
Remove the strut brace (B'16A2 engine).
8 x 1 .25 mm24 N.m {2.4 kgl.m, 17 lbf.ft}
Disconnect the battery cables from the under-hood
fuse/relay box and battery positive terminal.
STRUT BRACE
UNDER.HOODFUSE/RELAYBOX
BATTERY CABLES
5-2
ECM/PCM
(
5. Remove the battery and battery base.
8 x 1.25 mm24 N.m (2.4 kgf.m, 17 lbf ftl
7.
Disconnect the connectors from the ECM/pCM.
Disconnect the main wire harness connector.
MAIN WIRE HARNESSCONNECTOR

8. Remove the intake air duct and air cleaner housing.
D16Y, ongino:
a. Remove the resonator and intake air duct.
6x1.0mm9.8 N.m (1.0 kgt m, 7.2 lbf.tt)
INTAKE AIR
Disconnect the intake air tempsrature (lAT) sen-
sor connector, then r€move thg air cleaner hous-
Ing.
6x1.0mm9.E N.m (1.0 kgtm, t.2lbtft,AIR CI."EANERHOUSING
IAT SENSORCONNECTOR
016Y5, Dl6Y& 815A2 engin€sl
a. Disconnect the IAT sensor connector, then
remove the intake 8ir duct and air cleaner hous-
Ing.
6x1.0mm9.8 N m {1.0 kgtm, 7.2 lbl'ft)
AIR CITANERHOUSING
INTAKE AIRDUCT
IAT SENSORCONNECTOR
9. Disconnect the engine wire harness connector on
the left side of the engine compartment.
(cont'd)
5-3

Engine Removal/lnstallation
Removal (cont'dl
10. Relieve fuel pressure (see section l1).
!@ Do not smoke while working on the fuelsystem, Keep open flame or spark away from thewolk area. Drain fuel only inlo an approved container.
11. Remove the evaporative emission (EVAP) controlcanister hose and fuel feed hose.
D16Y7 engine:
BANJO BOLT33 N m ( 3.it lgt m, 25 lbt.ft)
FUEI- FEED HOSE
D16Y5, D16Y8, Bt642 engines:
5-4
I
12. Remove the brake
hose and vacuum
D16Y7 engine:
booster vacuum hose, fuel returnhose.
VACUUM HOSE
Dl6Y5, D16Y8, Bl642 enginos:
BRAKE BOOSTERVACUUM HOSE

13. Remove the throftle cable by loosening the locknut,
then slip the cable end out of the accelerator link-
age.
NOTE;
. Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one.
. Adjust the throttle cable when installing (see sec-
tion 1 1).
D16Y7 engine:
D16Y5, D16Y8, B16A2 engines:
LOCKNUT
LOCKNUT
14,Disconnect the connectors from the PCM.
Remove the grommet and wire harness clamps,
then pull out the ECM/PCM connectors
6x1.0mm
16. Remove the mounting bolt and lock bolt, then remove
the power steering (P/S) pump belt and pump
NOTE: Do not disconnect the P/S hoses.
816A2 engine:
Remove the adjusting bolt and mounting boits,
then remove the P/S pump belt and pump
(cont'd)
5-5
AOJUSTING

Engine Removal/lnstailation
Removal (cont'dl
Dl6Y5. DrGYr, D16Y8 enginas:
-1. Remove the mounting bolt and lock bolt, thenremove the P/S pump belt and pump.
MOUNTING BOLT8 x 1.25 mm24 N.m {2.4 kgl.m, 17 tbf.ftl
LOCK BOLT8 x 1.25 mm24 N.m 12.4 kgf.m, 17 lbf.ftl
17. Loosen the idler pulley center nut and adjustingbolt, then remove the air conditioning (A[/C)compressor belt.
IDI.IR PULLEY CENTERNUT10 x 1.25 mma,l N.m {,1.5 kgt.m, 33 lbf.ft)
5-6
(
'18. Remove the ransmission ground cable and hosect8mo.
HOSE CLAMP6 x '1.0 mm
19. Remove the clutch slave cylinder and line/hoseassembty (M/T).
NOTE:
. Do not disconnectthe pipe/hose assembly.. Do not operate the clutch pedal once the slavecylind€r has been removed.o Take care not to bend the line.
6x1,0mm 8x1.2Smm11 N.m {1.1 kgt.m, 2a N.m t2.4 kgf.m,I tbf.ftl 17 tbf.ftl
8 x 1.25 mm2a N'm {2,4 kgt m,17 tbt.ftl