Shaft HONDA CIVIC 1997 6.G User Guide

cwSection 14[Jnit of length: mm (in)
MEASUBEMENTSTANDARD {NEW}SERVICE LIMIT
Forward clutch end plate thickness Mark 1 or 15Mark 2 or 16Mark 3 or 17Mark 4 or 18Mark 5 or 19Mark 6 or 20Mark 7 or 21Mark 8 or 22Mark I or 23Mark 10 or 24Mark 11 or 25Mark 12 or 26Matk 13 ot 21
3.4 - 3.5 10.134 - 0.138)
3.5 - 3.6 (0.138 - 0.142)3.6 - 3.7 (0.142 - 0.146)3.7 3.8 (0.146 0.150)3.8 - 3.9 (0.150 - 0.154)3.9 - 4.0 (0.154 - 0.157i4.0 - 4.1 (0.157 - 0.161)4.1 - 4.2 (0.161 - 0.165)4.2 - 4.3 (0.165 - 0.169)4.3 - 4.4 (0.169 - 0.173)4.4 - 4.5 10.173 - 0.177i4.5 4.6 (0.177 0.181)4.6 - 4.7 (0.181 - 0.185)
Discoloration
Discoloration
Reverse brake end plate thickness Mark 1Mark 2Mark 3Mark 4\44 rk 5Mark 6Mark 7Mark 8
3.55 - 3.65 (0.140 0.144)3.75 - 3.85 10.148 - 0.152)
3.95 - 4.05 (0.156 - 0.159i4.15 - 4.25 (0.163 0.167)4.35 - 4.45 (0.171 - 0.175)
4.55 - 4.65 (0.179 - 0.183)4.75 - 4.85 (0.187 - 0.191)4.95 - 5.05 (0.195 - 0.199)
Discoloration
1
IDiscoloration
ATF pumpATF pump drive gear shaft O.D.ATF pump driven gear shaft O.D.ATF pump body bushing l.D. Drive gear shaftDriven gear shaft
ATF pump gear side clearanceATF pump gear-to-body clearance Drive gear
Driven gear
9.98 - 9.99 (0.3929 0.3933)9.98 - 9.99 {0.3929 - 0.3933)10.000 - 10.015 (0.3937 0.3943)10.000 - 10.015 (0.3937 0.3943)
0.01s - 0.035 (0.0006 0.0014)
0.035 - 0.0505 (0.0014- 0.0020)
0.035 - 0.0505 (0.0014 - 0.0020)
Wear or damagedWear or damagedWear or damagedWear or damaged
TransmissionDiameter of needle bearing contact areaInput shaft - flywheel sideInput shaft forward clutch sideDrive pulley shaft - start clutch sideDrive pulley shaft - flywheel side
Drive pulley shaft - forward clutch side
Thrust clearanceCarrier and ring gear
Driven pulley shaft and start clutch hub
Input shaft and ATF pump driven sprocketSecondary gear shaft and flywheel ball bearing
19.987 - 20.000 (0.7869 - 0.7874)19.987 - 20.000 (0.7869 - 0.7874)43.981 - 43.991 (1.7315 - 1.7319)24.007 - 24.020 (0.945 - 0.946)24.007 - 24.020 (0.945 - 0.946)
0.050 - 0.110 (0.0020 - 0.0043)
0.000 - 0.130 10.000 - 0.005)
0.370 - 0.650 (0.015 - 0.026)0.00 0.15 (0.00 0.006)
Wear or damagedWear or damagedWear or damagedWear or damagedWear or damaged
(cont'd)
3-15

Transmission(cont'd)
MEASUREMENT
Thrust shim,25 x 31 mm thickness
STANDARD {NEW}
rlz-r-osr-o.o+o oolrr1.09 - 1.12 (0.043 0.044)1.16 1.19 (0.046 - 0.047)1.23 1.26 (0.048 0.050)1.30 - 1.33 (0.051 0.052)1.37 - 1.40 (0.054 0.055)1.44 - 1.47 (0.057 0.058)1.51 1.54 (0.059 0.061)1.58 1.61 (0.062 - 0.063)1.65 - 1.68 (0.065 0.066)1.72 1.75 {0.068 0.069)1.79 1 .a2 t0.O10 - 0.012]}1.055 1.085 (0.0415 0.0427)1.125 - 1.155 (0.0443 0.0454)1.195 - 'I.225 (0.0470 0.0482)1.265 - 1.29s (0.0498 0.0510)1.335 1.365 (0.0526 - 0.0537)1.40s - 1.435 (0.0553 - 0.0565)r.475 1.505 {0.0580 0.0593)1.545 1.575 (0.0608 0.0620)1.615 1.645 (0.0636 - 0.0648)1.685 1.71510.0663 - 0.0675)1.755 - 1.785 {0.0691 0.0703)
SERVICE LIMIT
I Wr"r - d-"-"g"d
ii
11
ir
Cotters thickness2.87 - 2.90 (0.1 13 - 0.114)2.97 - 3.00 (0.117 0.118)3.07 -3.10 \0.121 0.122)3.17 - 3.20 (0.125 0.126)
Wear,or damaged
IWear or damaoedATF pump drive sprocket thrust shim, 22 x 28 mmthickness1.12 1.1510.044 - 0.045)1.37 1.40 (0.054 - 0.055)1.62 - 1.65 (0.064 0.065)1.87 - 1.90 (0.074,0.075)2.12 2.15 (0.083 - 0.08s)2.37 2.40 (0.093 0.094)
Wear or damaged
t
{Wear or damagedSecondary gear shaft thrust shim, 25 x 35 rnmthickness2.80 - 2.85 (0.1't0 - 0.112)2.90 2.95 (0.114 - 0.116)3.00 3.05 (0.118 - 0.120)3.10 -3.15 10.122 0.124)3.20 - 3.25 (0.126, 0.128i3.30 - 3.35 (0.130 0.132)3.40 - 3.4s 10.134 0.136)3.50 3.55 (0.138 - 0.140)3.60,3.65 (0.142 0.144)3.70 - 3.75 (0.146 0.148)3.80 - 3.8510.150 0.152)
Wear or damaged
Wear or damaqedInput shaft feed pipe O.D.Drive pulley leed pipeForward clutch feed pipeInput shaft bushing t.D.Drive pulley feed pipe bushingForward clutch feed pipe bushingDriven shaft feed pipe O.D.Start clutch feed pipe (right side cover side)Driven pulley feed pipeStan clutch feed pipe (ftywheet housing side)Driven pulley shaft bushing LD.Stan clutch feed pipe (right side cover sroerDrive pulley feed pipeStart clutch feed pipe (flywheel housing side)Secondary driven gear sealing ring groove widthStart clutch end plate l.D.Input shaft sealing ring groove widthDnve pullev shaft LD. at sealing ring
Park brake conePark brake pawlPark gear
6.97 - 6.98 (0.274 - 0.27s)11.47 - 1'1.48 (0.4516 0.4520)
7.O0O 7.0t510.2156 - 0.2762]l11.500 11.518 (0.4528 0.4535)
6.97 - 6.9A \0.214 0.275:l11.47 - 11.48 (0.4516 _ 0.4520)8.97 8.98 10.353 - 0.354)
7.000 7.015 (0.2756 - 0.2762)1 1.500 - '11.518 (0.4528 - 0.4535)9.000 9.015 10.354 - 0.355)2.50 2.65 (0.098 0.104)88.900,88.935 (3.500 - 3.501)2.00 2.10 10.079 - 0.083)
5*
6.95 (0.274)
11.45 (0.451)
7.030 (0.277)11.533 (0.4s4)
6.95 (0.274)
11.45 (0.451)
8 95 (0.352)
t.030l0.2t7l1r.533 (0.454)
9.03 (0.356)2.655 (0. r05)Wear or damaged2.105 (0.083)Wear or damaqedShifting deviceano parKbrake control
Wear or other defectWear or other defectWear or other defect
Standardsand Service Limits
CW {cont'd)Section 14
rl
w
3-16
ro

Unit of length: mm lin)
STANDARD {NEW) SERVICE LIMITMEASUREMENT
Differential
Dtri"*"t"|p'.b"gear
S"t rrg-t" b""il"s
Pinion shaft contact area LD.
Carrier-to pinion clearanceDrive shaft contact area l.D.Carrier to driveshaft clearance
BacklashLD.Pinion gear to-pinion shafl clearance
)uter race clearance
18.010 18.028'0.7091 - 0.7098)
0.023 0.057 (0.0009 - 0.0022) 0.1 (0 004)
26.025 - 26.045 (.0246 1 0254\0.045 0.086 (0.0018 - 0.0034) 0.12(0.005)
0 05 - 0.15 i0 002 0.006)18 042 18.066 {0.7103 0.7" l3)
0.055 - 0.095 (0.0022 - 0.0037) 0.15 {0.006)
0 0.15 (0 - 0.006) Adjlrst
MEASUBEMENT Wire DiaO.D. Free Length I No. of Coils
SpringsPH regulator valve spring 1 2 (0 047)
PH control valve spring 1 7 {0.067)PL regulator valve spring 0 9 (0.035)
PH'PL control valve spring 1 0 (0 039)
crutlh reduc'ns vdrve spnns ] :19 9]:lLLbrication valve spring I b (u ubJr
Shitt valve spring 1 4 (0.055)
Shift control valve spring 1 0 (0.039)
Stan clutch control valve spring 0.4 (0 016)
Pitot regulator valve spring 0.6 (0 024)
Start clutch valve accumulator spring 1 2 \0 O47)
Reverse control valve spring 1 2 (0.047)
Shift inhibitor valve spring 1 3 (0 051)
9.0 {0.354)13.4 (0.528)
1.2lO.2A3\10.0 (0.394)
16.8 (0.661)
13.4 (0.528)
8.2 (0.323)
1 .4 t0.29114.1 (0.161)
5.7 t0.224)8.3 {0.327)9.4 (0.370)
13.2 (0.520)
26.7 (1.051)
39.4 (1.551)
14.6 (0.575)
31.4 (1.236)
44.4 \1.14al51.6 (2.031)
34.1 (1.343)
19.3 (0.760)
12.1 (0.476)
9.5 (0.374)
29.8 (1.173)
31.4 (1.236)
48.3 (1.902)
r0.08.11.28.68.0
13.01.56.85.012.311.010.6
Section 14
SteeringSection 17
M/S: [,4anual steering, P/Sl Power steering*: When using a ne; bett, adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
Readjust the deflection or tension to used belt values.
cw
MEASUREMENTSTANDARD {NEWI
Steering wheelPlay at steering wheel circumferenceStarting load at steering wheelcircumferenceN (ksf, lbf)Manual steeringPower steering Engine running
0 - 10 (0 0.4)
15 (1.5,3.3)
29 (3.0,6.6)
GearboxAngle of rack guide screw loosened M/S
from locked position P/S
Preload at pinion gear shaft N m (kglcm, lbfin) M/S
20!5"20'Max0.5 - 1.7 (5 - 17,4.3 - 14.8i
0.6 1.2 (6 - 12, 5.20 - 10.42)
Pump pressure with valve closed(oil temp./speed: 40'C (105"F) min./idleDo not run for more than 5 seconds).kPa (kgtcm?, psi)
6,400 - 7,400 {65 - 75, 920 - 1,070)
Power steeringfluidRecommended power steering fluid
Fluid capacity | {US qt, lmp q0Reservoir
HONDA Power Steering Fluid
0.85 (0.90,0.75) at disassembly0.4 {0.42.0.35}
7.5 11.0 {0.30 - 0.43)with used belt
5.0 7.0 (0.20 0.28) with new belt10.5 - 14.0 10.41 - 0.55) with used belt7.5 10.010.30 0.39) with new belt
390 540 {40 55,88 '120) wrth used bek
340 - 490 (35 - 50, 77 - 110) with used belt
740 880 (75 - 90, 170 - 200) with new belt
640 780 (65 - 80, 143-176)with newbelt
Power steeringbelt*
Deflection with 98 N (10 kgf,22 lbf)
between pulleys '99 modell 81642 Engine Type only
'96 '99 models: Other Engine TYPes
ron.ionffiN (kgf, lbf) '99 model: 81642 Engine Tvpe only'96 -'99 models: Other Engine TYPes'99 modelr 81642 Engine TYPe onlY'96 '99 models: Other Engine TYPes
3-17

81642 engine:
8 x 1.25 mm
22N,n 12 2 kdl'rn,
Replace.
,&16 rbt.ftl
Replace.
SELF.LOCKING8 x 1.25 mm16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
GASKETSReplace.
10 x 1 .25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
32.
PIPE A
RePlace'
Remove the damper forks (see section 18).
Disconnect the suspension lower arm ball joints
(see section 18).
Remove the driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may
com9 apart.
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
NoTE: Coat all precision-finished surfaces with
clean engine oil. Tie plastic bags over the driveshaft
enos.
34.
HO2S CONNECTOR
!^.
35.
36.
Lower the hoist.
Remove the upper and lower radiator hoses and
heater hoses,
37. Removs the ATF cooler hoses, then plug the ATF
cooler hoses and PiPes (A,/T)
UPPERRADIATOR HOSE
HOSES
(cont'd)

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
\
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,

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

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

6. Tighten the locknut, and check the clearance again.
Repeat the adjustment if necessary.
GAUGE
7.Rotate the crankshaft 180' counterclockwise (cam-
shaft oullev turns 90'1. The "UP" mark should be on
the exhaust side. Adjust valves on No. 3 cylinder.
"UP- MARK
t
8. Rotate the crankshaft '180' counterclockwise to
bring No.4 piston to TDC. Both TDC grooves are
once again visible. Adjust valves on No. 4 cylinder.
Rotate the crankshaft 180'counterclockwise to bring
No. 2 piston to TDC. The "UP" mark should be on
the intake side. Adjust valves on No. 2 cylinder.
-UP'MARK
6-13

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

10. Using a downward motion on the lever arm, com-
.press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spring.
11. Remove the valve seals (see page 6-38).
12. Install the valve seals {see page 6-43).
13. Install the springs, the retainers and the keepers in
reverse order of removal.
Exhaust Valvs Sesls:
Select the 7/8 in. diameter short compressor attach-
ment, and fasten the attachment to the No. 2 hole of
the lever arm with the speed pin supplied.
Position the lever arm under the cross shaft so the
lever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for the
spring being compressed. Use the front position
slot on the lever as shown.
'14.
IN-CAR SPRING COMPRESSOR
7/8 in SHORT ATTACHMENT
L
16.Using a downward motion on the lever arm, com-
press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spnng.
Remove the valve seals {see page 6-38),
Install the valve seals (see page 6-43).
Install the springs, the retainers and the keepers in
reverse order of removal.
Repeat steps 6 to 19 on the other cylinders.
't7.
'18.
19.
20.
6-15