Piston HONDA CIVIC 1997 6.G Owner's Guide

Pistons and Crankshaft
Removal
1. Remove the oil pan assembly.
2. Remove the right side cover.
816A2 engine
D16Y5, Dl6Y7, D16Y8 ongines
RIGHT SIDE
7-12
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3. Remove the oil screen.
4. R€move the oil pump.
816A2 engin€
OIL SCREEN
D16Y5, D1oyr, D16Y8 engin.s
O-RINGReplace.
5, Remove the baffle plate (816A2 engine).
OIL PUMP

6. Remove the bolts and the bearing caps.
CAUTION: To prevenl warpago unscrow lhe bolts
in s€quence 1/3 turn at a tims, r€paat the soquence
until all bolts ar€ loo3ened.
MAIN BEARING CAP BOLTS LOOSENING SEOUENCE
Remove the rod caps/bearings and main capvbear-
ings. Keep all caps/bearing in order.
Lift the crankshaft out of the engine, being careful
not to damage journals.
7.
S:_]ILOJLOAO
CRANKSHAFT14.
7-13
qRemove the upper bearing halves from the connect-
ing rods and set them aside with their respective
caos.
Reinstall the main caps and bearings on the engine
in proper order,
lf you can feel ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge
reamer. Follow the reamer manufacturer's instruc-
I|ons.
CAUTION; lf the ridge is not removed, it may dam-
age tho pistons as they are pushod out.
RIOGE REAMER
10.
11.
12.Use the wooden handle of a hammer to drive the
pastons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
Mark each piston/connecting rod assembly with its
cylinder number to avoid mixup on reassembly.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.

Pistons
Inspection
1.Check the piston for distortion or cracks,
NOTE: lf a cylinder is bored. an oversized piston
must be used.
Measure the piston diameter at a distance A from
bottom of the skirt.
816A2 engino:
A: 15 mm 10.6 in)
D16Y5, D16Y7, D16Y8 engines:
A: 5 mm (0.2 inl
Piston Diameter:
816A2 engine:
Standard lNewl: 80.980 - 80.990 mm
13.1882 - 3.1886 in)
Service Limit: 80.970 mm (3.1878 in)
D16Y5, D16Y7, D16Y8 engines:
Standard {New): 7,f.980 - 7i1.990 mm
|.2.9520 - 2.9521in!
Service Limit: 74.970 mm {2.9516 inl
SKIRT DIAMETER
57-1
3. Calculate the difference between the cylinder bore
diameter (see page 7-16) and the piston diameter.
Piston-to-Cylinder Clsarance
Standard lNewl: 0.010 - 0.0,10 mm
(0.0004 - 0.0016 inl
Servico Limit: 0.05 mm {0.002 in}
lf the clearance is near or exceeds the service limit,
inspect the piston and cylinder block for excessive
wear.
Oversizo Piston Diametor
816A2 ongine:
0.25t 81.23 - 81.21 mm (3.1980 - 3.1984 inl
D16Y5. D16Y7, D16Y8 engines:
O.25t 75.23 - 75.21 mm (2.9618 - 2.9622 in)
0.50: 75.i18 - 75.49 mm {2.9716 - 2.9720 in}

Cylinder Block
Inspection
'LMeasure wear and taper in directions X and y at threelevels in each cvlinder as shown.
Cylinder Boro Size
816A2 engine:
Standard (Newl: 81.00 - 81.02 mm
{3.1t|:l - 3.190 intService Limit: 81.07 mm {3.192 in)D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 75.00 - 75.02 mm(2.9s3 - 2.954 in)
Sarvice Limit: 75.07 mm (2.956 in)
Oversize
816A2 engiDe:
0.25t 41.25 - A1.27 mm {3.199 - 3.200 in)D16Y5, D16Y7, D16Y8 Engines:
0.25t 75.25 -15.27 mm (2.9626 - 2.963,0 in)0.50: 75.50 - 75.52 mm 12.9721- 2.9i32 inl
Bore TaDet
Limit: (Difference between first and third measure"ment) 0.05 mm (0.002 inl
7-16
lf the measurements in any cylinder are beyondthe Oversize Bore Service Limit, replace the block.
lf the block is to be rebored. refer to piston Clear-ance Inspection (see page 7-15) after reboring.
NOTE: Scored or scratched cylinder bores must behoned.
Reboring Limit:
Bl642 enginc:
0.25 mm (0.01 in)
Dl6Y5, D16Y7, D16Y8 engin€s:
0.50 mm (0.02 in)
Check the top of the block for warpage,Measure along the edges and across the center asshown.
SURFACES TO BE MEASUREO
Engine Block Warpage:
Bl6A2 engine:
Standard (Now): 0.05 mm {0.002 inl max.Service Limh: 0.08 mm (0.003 in)DtOYs, D16Y7, D16Y8 €nginas:
Standard (N€w): 0.07 mm l0.OO3 inl max.Servica Limit; 0.10 mm {0.00it in)
PRECISION STRAIGHT EDGE

Cylinder BlockPiston Pins
Bore Honing
1.Measure cylinder bores as shown on page 7-16. lf the
block is to be reused, hone the cylinders and remea-
sure the bores.
Hone cylinder bores with honing oil 8nd a fine (400
grit) stone in a 60 degree cross-hatch pattern.
NOTE:
. Use only a rigid hone with 400 grit or finer stone
such as Sunnen, Ammco, or equivalent.
. Do not use stones lhat are worn or broken.
When honing is complete, thoroughly clean the
engine block of all metal particles. Wash the cylin-
der bores with hot soapY water, then dry and oil
immediately to prevent rusting.
NOTE: Never use solvent. it will only redistribute the
grit on the cylinder walls.
lf scoring or scratches are still present in cylinder
bores after honing to the service limit, rebore the
cylinder block.
NOTE: Some light vertical scoring and scratching is
acceptable if it is not deep enough to catch your fin-
gernail and does not run the full length of the bore.
CYLINOES BLOCK
CYLINDER
NOTE:
. After honing, clean the cylinder thoroughly with
soapy warer.
. Onlv a scored or scratched cylinder bore must be
noneo.
Removal
l. Assemble the special tool as shown.
PISTON BASE HEAD07973 - SBtx)too
ft
PISTON PIN BASE
INSERT01973 - PE00'0)
ptn
NOTEi Us6 a hydraulic press.When pressing the pin in or out.make sure that the recesssdportion of the piston alignswith the lips on the collar.
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2. Assemble and adjust the length of the piston
driver and shaft to 53 mm (2.1 inl as shown.
PISTON PIN DRIVER HEAD07973 - PE00320
Proat
0
PISTON PINDRIVER SHAFT0t973 - PEqr310
PILOT COLLAR07973 - PE00200
3. Place the piston on the sp€cial tool and press the
pin out with the special tools and a hydraulic press.
Emboss6d mark facing up
7-17

Connecting RodsPiston Pins
Selection
Each rod falls into one of four tolerance ranges {from O to+ 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)increments) depending on the size of its big end bore. lt,sthen stamped with a number {1, 2,3, or 4) indicating therange.
You may find any combination ot l, 2, 3, or 4 in any
engrne.
Normal Eore Size: 48.0 mm (1.89 in)
NOTE:
o Reference numbers are for big end bore size and doNOT indicate the position of the rod in the engine.. Inspect connecting rod for cracks and heat damage.
CONNECTING ROD AOREREFERENCE NUMBERHalf of number is stamped onbearing cap, the other half onconnectrng rod.
7-18
Installation
1. Use a hydraulic press for installation.
. When pressing the pin in or out, be sure you posi
tion the recessed flat on the piston against the lugson the base attachment.
816A2 engine
The arrow must face thetiming belt side of theeng Ine.
The mark must facethe timing belt sideof the engine.
D16Y5, D16Y7, O16Y8 engines
The arrow must face thetiming belt side o{ theengine and the connectingrod oil hole must face therear of the engine.
Adjust the length of thepiston pin driver to53 mm (2.09 4n)
PISTON PIN DRIVER SHAFT07973-PEOo3r0
PISTON PIN DRIVER HEAD
il--Z
P,"roNPrN
PILOT COLLAR07973-PE00200
PISTON PIN BASE INSERT07973 PEO0400
PISTON EASE HEAO07973 -5800100
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lnspection
1.
Oversize:
Oversize:
NOTE; All replacement piston pins are overslze.
2. Zero the dial indicator to the piston pin diameter'
Measure the diameter of the piston pin.
Piston Pin Diametel:
B16A2 engine:
Standard {New): 20.994 - 21.000 mm
(0.8265 - 0.8268 in)
20.997 - 21.003
10.8267 - 0.8269 inl
D16Y5, Dl6Y7, Dl6YB engines:
Standard lNewl: 18.99,1- 19.000 mm
(0.7478 - 0.7480 inl
18.997 - 19.003
{0.7479 - 0.7481 in)
3. Measure the piston pin-to-piston clearance.
NOTE: Check the piston for distortion or cracks.
lf the piston pin clearance is greater than 0.024 mm
(0.0009 jn), remeasure using an oversized piston
pin.
Piston Pin-to-Piston Clearance:
Standard (New): 0.010 - 0.022 mm
(0.0004 - 0.0009 in)
Check the difference between the piston pin diame-
ter and the connecting rod small end diameter'
Piston Pin-to-Connesting Rod Interterence:
816A2 engine:
Standard (New): 0.013 - 0.032 mm(0.0005 - 0.0013 in)
D16Y5, D16Y7, Dl6YB engines:
Siandard lNewl; 0.014 - 0.040 mm
4.
10.0006 - 0.0016 inl
7-19

Piston Rings
End Gap
1.Using a piston, push a new ring into the cylinderbore 15 - 20 mm (0.6 - 0.8 in) from the bottom.
Measure the piston ring end-gap with a feeler gauge:
. lf the gap is too small, check to see if you have
the proper rings for your engine.. lf the gap is too large. recheck the cylinder borediameter against the wear limits on page 7-16,
lf the bore is over the service limit, the cvlinderblock must be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd (New): 0.20 - 0.35 mm
{0.008 - 0.01,1 in)
Service Limit: 0.60 mm l0-02i1 inl
D16Y5. Dl6Y7, D16Y8 enginos
Standard lNewl: 0.15 - 0.30 mm
{0.006 - 0.012 in)
Ssrvic€ Limit 0.60 mm {0.024 inl
Socond Ring
816A2 ongina
Standard (Nowl: 0.40 - 0.55 mm
10.016 - 0.022 inl
Service Limit: 0.70 mm (0.028 inl
D16Y5, D16Y7, Dt6Y8 engines
Standard (New): 0.30 - 0.ia5 mm
{0.012 - 0.018 in)
Sorvice Limit 0.70 mm 10.028 inl
Oil Ring
81642 ongine
Standard {Now): 0.20 - 0.50 mm(0.008 - 0.020 inl
Sorvico Limit: 0.70 mm (0.028 in)
Dl6Y5. Dl6Y7, D16Y8 €nginos
Standard (Nowli 0.20 - 0.70 mm(0.008 - 0.028 inl
Servica Limit: 0.80 mm 10.031 in)
7-20
Replacement
1.Using a ring expander. remove the old piston rings.
Clean all ring grooves thoroughly.
NOTE:
. Use a squared-off broken ring or ring groove
cleaner with blade to fit piston grooves.
o Top ring groove is 1.0 mm (0.039 in)wide.. Second ring groove is 1.2 mm (0.047 in) wide.. Oil ring groove is 2,8 mm (0.11 in) wide.. File down the blade if necessary.
CAUTION: Do noi use a wire blush to clean ringlands. or cut ring lands deepol with cleaning tool.
NOTE: lfthe piston is to be separated from the con-necting rod, do not install new rings yet.
3. Install new rings in the proper sequence and posi-
taon (see page 7-22).
NOTE: Do not reuse old piston rings.
(Commercially available)

Ring-to-Groove Clearance
After installing a new set of rings, measure ring-to-
groove clearances:
Top Ring Clearance
Standard (New):
B16A2 angine:
0.045 - 0.070 mm (0.0018 - 0.(X128 in)
Dl6Y5, Dt6Y7, Dl6Y8 engin€s:
0.035 - 0.060 mm {0.0014 - 0.002'l in)
service Limit: 0.13 mm (o.fixi in)
Second Ring Clearance
Standard lNow):
B16A2 engine:
0.0/t0 - 0.065 mm (0.0016 - 0.0026 in)
Dl6Y5, D16Y7, D16Y8 onginos:
0.030 - 0.055 mm (0.(X)12 - 0.0022 in)
Sewica Limh: 0.13 mm (0.005 io)
.,o
Alignment
1. Installthe rings as shown.
NOTE: The manufacturing marks must be facing
upward.
SECOND RING (Darkl
Piston Ring Dimsnsions:
Unit mm (in)
Unit mm (in)
TOP RING (Chrome)
t----T f
lB
t---f_-L
A
Top Ring (Standard)
Second Ring (Standard)
B
Bl642 engine3.1 (0.12)1.0 (0.04)
D16Y5, D16Y7,
D16Y8 engines2.6 (0.10)1.0 (0.04)
B
816A2 engine3.3 (0.13)1.2 (0.05)
D16Y5, D16Y/.
D16Y8 engines3.0 (0.12)1.2 {0.05t
(cont'd)
7-21

Piston RingsCrankshaft Oil Seal
Alignment (cont'dl
TOP RING ---.>
SECOND RING >
MARK
,a-)
/\_4
o,.r^o( qffi<--sPACER
\Z-.
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Rotate the rings in their grooves to make sure theydo not bind.
Position the ring end gaps as shown:
DO NOT position any ring gapat piston thrust surfaces.
DO NOT position any ring gapin line with the piston pin hole.OIL RING GAP
SECOND RING GAP
Approx.90
TOP RING GAP
7-22
Installation
The seal surface on the block should be dry.Apply a light coat of oil to the c.ankshaft and tothe lip of the seal.
1. Drive the crankshaft oil seal squarely into the right
side cover using the special tools.
HANDLE DRIVER07749 0010000
seal with thepan number sidefacing out.
Confirm that the clearance is equal all the way
around with a feeler gauge.
Clearance:0.5 - 0.8 mm (0.02 - 0.03 inl
NOTE: Refer to page 8-14 for installation of the oilpumo side crankshaft oil seal.
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