removal HONDA CIVIC 1997 6.G Owner's Guide

Cylinder Head
19.
20.
Removal (cont'dl
Remove the timing belt {see page 6-62).
Remove the back cover and camshaft pulleys.
BACK COVER
56 N.m (5.7 kgf m,
41 tbt.f06xl.0mm9.8 N,m (1.0 kgf.m, 7.2 lbf.ft)
21, Remove the exhaust manifold (see page 9-8).
22. Remove the intake manifold (see page g-5).
23. Loosen the adjusting screws.
INTAKE
No.4 No.3 No.2 No. 1
6-70
24. Remove the camshaft holder plates, camshaft hold-ers and camshafts.
CAMSHAFTHOLDER PLATE
Remove the cylinder head bolts, then remove the
cylinder head.
CAUTION: To prevsnt warpage. unscrew the bolts
in sequonc€ 1/3 turn at a tim€; lepeat lh6 sequence
until all bolts aro loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE:
CYLINDER HEADPLUGReplace. t
\1
\€\i
b4CAMSIIAFTS -

Rocker Arms
Removal
'1. Hold the rocker arms together with a rubber band to
prevent them from separating.
Remove the intake and exhaust rocker shaft oil con-
trol orifices, then remove the VTEC solenoid valve
and the sealing bolts.
NOTE: The shapes ofthe intake and exhaust oil con-
trol orifices are different, ldentify the parts as they
are removed to ensure reinstallation in the original
locauons.
2.
EXHAUST ROCKERSHAFT ORIFICE
INTAKE ROCKERORIFIGEClean.Clean.
O.RINGO.RINGReplace.
RUEBER BAND
Replace. _ (lX
-dJ'v-l- \
6-71
3. Screw 12 mm bolts into the rocker arm shafts.
Remove each rocker arm set while slowly pulling
out the intake and exhaust rocker arm shafts.
12 mm BOLTS
ROCKER ARM SHAFTS

Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are
removed so that each item can be reinstalled in its origi-
nal Dosition.
l. Using an appropriate-sized socket and plastic mal-
let, lightly tap the valve retainer to loosen the valve
keeoers.
PLASTIC
Install the valve spring compressor. Compress the
spring and remove the vSlve keepers.
VALVE SPRINGCOMPRESSORATTACHMENT07757 - PJ1010A
VALVE SPRINGCOMPRESSOR ATTACHMENTEXTENSIONOTMAF - PRgOIOA
I
Sn.p-on CFr1lCOMPRESSOR
6-77
3. Installthe valve guide seal remover.
VALVE GUIDE SEAL REMOVERCOMMERCIALLY AVAILABLELtst-E P/N 571100 ()R KD3350
4. Remove the valve guide seal.
Valve Dimensions
lntake Valvo
A Standsrd {Newl; 32.90 - 33.10 mm (1.295 - 1.303 in}
B St ndard {New}: 101.00 - 101.30 mm (3.976 - 3'988 in}
C Stsndard (Nowl: 5./t5 - 5.,185 mm (0.2156 - 0.2159 in)
C Servico Limit 5.445 {0.21/l| in)
D Siandard (N!w): 1.05 - 1.35 mm (0.041 - O.05il inl
D S€.vice Limit: 0.85 mm {0.033 inl
Exhaust Valve
A Standard lNewli 27.90 - 28.10 mm (1.098 - 1.106 in)
B Stlndard {Nowl: 100.m - 1qr,90 mm {3.961 - 3.972 in)
C Stsndard {Now}: 5.450 - 5.,[60 mm {0.21,16 - 0.2150 in)
C Service Limit 5.420 10.213,0 inl
D Standard {New): 1.65 - 1.95 mm (0.065 - 0.077 in)
D Sorvico Limit: l.ils mm 10.057 inl

t
Valve Guides
Replacement
1. As illustrated below, use a commerciallv available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. ln most
cases, the same procedure can be done using the
sDecial tool and a conventional hammer.
COMMERCIALLY AVAILABLEVALVE GUIDE DRIVER
87 mm -L- sz mm(3.43 inl I tz.zr int
rE-tt
10.8 mm10.42 inl
olVALVE GUIOE DRIVER,5.5 mm077,P - 0010100
Select the proper replacement guides and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150"C). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warp tho head.. Do not get tho head hotter than 300"F {150"C};excesgive heat may loosen thg valve seats.. To avoid burns. use haaw gloves whon handling
the heatod cylinder head.
6-80
Working from the camshaft side, use the driver and
an air hammer to drive the guide about 2 mm (0.1 in)
towards the combustion chamber. This will knock off
some ofthe carbon and make removaleasier.
CAUTION:
. Always wsar safety goggles or a face shield whsn
driving valve guides.
. Hold the air hammer dir€ctly in line with the
valve guide to prevont damaging thg dtiver.
Turn the head over and drive the guide out toward
the camshaft side of the head.
VALVE GUIOE DRIVER,5.5 mm077{2 - 0010100
lf a valve guide still won't move. drill it out with a8.0 mm (5/16 in) bit, then try again.
CAUTION: Drill guides only in extreme cases; you
could damago the cylinder head if ths guide br6aks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
-:^-,65i^q
NNSp-<

Rocker Arms
lnstallation
1.
2.
3.
lnstall the rocker arms in the reverse order of
removal:
. Valve adjusting locknuts should be loosened and
the adiusting screw, backed off before installa-
tron.
. The component parts must be reinstalled in the
original locations.
lnstall the lost motion assemblies.
lnstall the rocker arms while inserting the rocker
arm shaft into the cylinder head
NOTE: Remove the rubber band after installing the
rocker arms.
12 mm BOLT
\
6-83
4. Clean and install the rocker shaft orifices with new
O-rings. lf the holes in the rocker arm shaft and
cylinder head are not in line with each other, screw
a 12 mm bolt into the rocker arm shaft and rotate
the shaft.
NOTE: The shapes of the rocker shaft orifices tor
the intake and exhaust are different. The orific'
must be installed in the proper locations.
INTAKE ROCKER
SHAFT ORIFICE
EXHAUST ROCKER Clean
SHAFT ORIFICE
O.RING
O

I
Cylinder Head
Installation
lnstall the cylinder head in the reverse order of removal:
NOTE:
. Always use a new head and manifold gasket.. The cylinder head gasket is a metal gasket, Take carenot to bend it.
. Rotate the crankshaft, set the No. 1 piston at TDC (seepage 6-63).
. Do not use the middle cover and lower cover forstorang removed items.. Clean the middle cover and lower cover before instal_lation.
o Replace any washers that are damaged or deteriorated.
1. Install the cylinder head gasket, dowel pins and thehead oil control orifice on the cylinder head.
NOTE: Clean the oil control orifice when installing.
DOWEL PIN
6-84
2, Tighten the cylinder head bolts in two steps. In thefirst step, tighten all bolts in sequence to about 29N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten inthe same sequence to 83 N.m (8.S kgf.m,6t lbf.ft).
NOTE:
. Apply clean engine oil to the bolt threads andunder the bolt head.. We recommend using a beam-type torquewrench. When using a preset-type torque wrench,be sure to tighten slowly and not to overtighten.. lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLT TOROUE SEOUENCE
11x 1.5 mm83 N.m 18.5 kgf.m, 61 tbf.ftl
Install the intake manifold and tighten the nuts in acflsscross pattern in two or three steps, beginningwith the inner nuts.. Always use a new intake manifold gasket.
Install the exhaust manifold and tighten the newself-locking nuts in a crisscross pattern in two orthree steps. beginning with the inner nuts.. Always use a new exhaust manifold gasket.
4.

Engine Block
Speciaf Tools ..........." 7-2
lllustlated Index ...................."..'.......... 7-3
Flywheel and Drive Plate
Repf acement """'.' 7-7
Connecting Rod and Crankshaft
End Play ..........."....7-8
Main Bearings
Clearance ............... 7-9
Selection ................7-10
Connecting Rod Bearings
clearance ....'.......... 7-11
Selection ................ 7-11
Pistons and Crankshaft
Removaf ................. 7 -12
Crankshaft
Inspection ."".........7-14
Pistons
Inspection ......"'.....7-15
fnstaffation .............7-23
Cylinder Block
lnspec'tion ..............7-16
Bore Honing ..........7-17
Piston Pins
Removal ...,...........'.7-17
lnstallation .............7-18
Inspection .'............7-19
Connecting Rods
Selection ................7-18
Piston Rings
End Gap ..........".."' 7'2O
Repfacement .........7-2O
Ring-to-Groove Clearance ...........'.'. 7 -21
Afignment .......""'.. 7'21
Crankshaft Oil Seal
fnstaffation .............7-22
Crankshaft
fnstaffation ..-.-..'.".' 7'23
Oil Pan
lnstallation .............7-26
Oil Seals
fnstaffation ....""""' 7-29
r-f

lllustrated Index
I runricate att internal parts with engine oil during reassembly'
NOTE:
o Apply liquid gaskettothe mating surfaces ofthe right side cover and oil pumpcase before installingthem'
. Use liquid gasket, part No 08718-0001 or08718-0003'
. Clean the oil pan gasket mating surfaces betore installing the oil pan
81642 engine:
DRAIN BOLT44 N,m {4.5 kgf'm,33 lbt'ft)
6 x 1.0 mm'11 N.m (1.1 kgI'm,
I tbl.ft)
OIL PANReter to page 7 27when installing.
6 r 1.O mm12 N.m t1.2 kgl'm, 8 7 lbf'lt)
OIL PAN GASKET
BUFFLE PLA
12 x 1.0 mm103 N.m {10.5 kgf'm,
76 tbr.ft)
6 x 1.0 mm11 N.m (1 .1 kgf.m,
8 tbI.fr)
GASKETReplace.FLYWHEEL(M/TI
12 x 1.0 mm
74 N.m (7.5
kof.m, 54 lbf'ft)
1^c{Eb\%^ t*^
*o"rr^--(Wffi
oa*,trto2,.w
FLYWHEEL COVER
IM/T)
DRIVE PLATECOVER (AiT)
11 x 1.5 mm76 N.m (7.9 kgf'm, 56 lbf'ft)
Apply engine oil to the bolt
threads.NOTE: After torqurngeach cap, turn crankshaft
to check for binding.
MAIN EEARING CAP
MAIN BEARINGSSelection, page 7_10
NOTE: New main bearings musl
be selected bY matching crank
and block identification markrngs
CRANKSHAFTInstallation, Page 7'23
OIL JET BOLT16 N.m 11.6 kgf'm, 12 lbl'ft)
OIL JETInspection, Page 8_10
Check for cracks
6x1.0mm11 N.m {1.1 kgf'm, I lbf'ft}
CRANKSHAFT OIL SEAL
Installation,pagesl 22 andl 29
Replace-
DOWEL PINOIL PUMPOverhaul, page 8-'l1Removal/lnspection,page 8-13.Apply liquid gasket
to mating surlace.RIGHT SIDE COVERApply liquid gasket
to mating surface.
THRUST WASHERS8 x 1.25 mm24 N.m {2.4 kgf.m, 17 lbf'ft)Grooved sides face outward
NOTE: Thrusr washer thickness
is tixed and must not be changed
by grinding or shimming
O-RINGReplace
CRANKSHAFT SEAL11 N.m {1.1 kgf'm, lnstallation, pages 7'29 and I 14
a lbt.ltl Heplace. (cont'd)
d#*

D16Y5, D16Y8 engines:
DRAIN BOLT39 N.m 14.0 kgt'm,
Apply liquid gasket to
these points.
OIL PANRefer to page 7-25
when installing.WASHERReplace.
29 lbl.tt)
\
\^
6 x 1.0 mm q%
P
I
FLYWHEEL COVER(M/T}
12 x 1.0 mm118 N.m(12.0 kgt.m, 87 lbt'ft)
FLYWHEEL (M/TI
t2 N.m 11.2 kgf'm,
8.7 lbl.ftl
11 x 1.5 mm
51 N.m(5.2 kgf'm, 38 lbf ftl
Apply engine oiltothe bolt
threads.NOTE: Aftertorquingeach cap, turn crankshaft
to check for binding.
MAINBEARING
MAIN BEARINGSSelection, page 7-10NOTE: New main bearings must
be selected by matching crank
"nJ lr."i io"irriti"",ion-markings. --------*-i6{\
CRANKSHAFTInstallation, page 7-23
6 r 1.0 mm11 N.m (1 1 kgf'm, I lbf'ttl
OII PAN GASKETReplace.
DRIVE PLATE COVER
{A/T or CVT)
12 r 1.0 mm
74 N.m
17.5 kgl.m, 54 lbf'ft)
DBIVE PLATE {A/T or CVTI
Check for cracks
6 x 1.O mm11 N.m {1.1 kgl'm,
8 tbl.ftl
CRANKSHAFT OIL SEAL
lnstallation,pages 7'?1 and '1 '28
Replace.
RIGHT SIDE COVER
Apply liquid gasket
to mating surface.
OIL SCREEN
GASKETReplace.
OIL PUMPOverhaul, page 8_12Removal/lnspection,page 8-13Apply liquid gasket
to mating surface.
DOWEL PIN
WASHEFS
Grooved sides tace outward
NOTE: Thrust washer thickness
is fixed and must not be changed
bV grinding or shimming.
CRANKSHAFT SEALInstallation, pages 7 29
and 8-14Replace.
BREATHING PORT COVER
MOUNT BOLTS6 x 1.O mm11 f{..n (1.1 kgf'm, 8 lbf'fl)
Apply liquid gasket to
the bolt threads.
O.RINGReplace.
6 x 1.0 mm
11 N.m (1 1 kgl'm,
8 tbr.ftl
(cont'd)
7-5
\
OOWEL PIN

lllustrated Index
(cont'd)
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft(see page 7,11).identification markings
Lubricate all internal parts with engine oil duringreassembtv.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTON RINGSReplacement. page 7-20Measurement, pages 7 20 andj-21Alignment, page 7-21
PISTON PINRemoval, page 7,17Installation, page 7-18Inspection, page 7,19
CONNECTING RODEnd play, page 7-8Selection, page 7,18
CONNECTING RODBEARINGSClearance, page 7 11Selection, page 7-11
CONNECTING ROD BEARING CAPInstallation, page 7-23NOTE: lnstall caps so thebearing recess is on thesame side as the recessin the rod.
PISTONInspectron, page 7-15NOTE: Betore removing the piston, inspect thetop of the cylinder bore for carbon build-up orridge. Bemove ridge if necessary, page 7-13
ENGINE BLOCKCylinder bore inspection, page 7-16Warpage inspection, page 7,'16Cylinder bore honing, page 7,17
Inspect top of each cylinder borefor carbon build-up or ridgebefore removing piston.Remove ridge if necessary, page 7-13
CONNECTING ROD CAP NUT816A2 €ngin6:9 x 0.75 mm{0 N.m (4.1 kgt m, 30 tbf.ftlD16Y5, Dl6Y7. D16Y8 engines:8 x 0.75 mm3l N.m {3.2 kg{.m,23 tbt.fr)Apply engine oiltothe bolt threads.NOTE: After torquing each bearingcap, rotate crankshaft tocheck for binding.
7-6