D16Y5 HONDA CIVIC 1997 6.G Workshop Manual

Chassis and Paint Codes
U.S. 1996 Model (2-door Coupe)
Vehicle ldentif ication Number
and Federal Motor Vehicle
Safety Standard Certification
IHG EJ6 12*T L 000001
Line. Body and Engine Type
EJ6: CIVIC 2-doorD16Y7
EJ7: ClVlC 2-doorD l6Y5
EJ8: ClVlC2-door/D16Y8
Body Type and Transmission Type
Check Digit
Model Year
T: 1996
L: East Liberty, Ohio Ptant, U.S.A.
1:Coupe/s-speed
Ma nua I
2: Coupe/4-speed Automatic, CVT
4: DX with A'lC, HX with A,,/C, EX
5: DX with ABS and A,/C, EX with ABS
ofEngine Number
Engine Type
D16Y5: 1600 SOHC WEC E 16-vatves
Sequential Multiport
Fuel-injected Engine
D 16Y7: 1600 SOHC 16-vatves
Sequential Multiport
Fuel-injected Engine
D16Y8: 1600 SOHC WEC 16-vatves
Sequential Multiport
Fuel-injected Engine
Serial Number
JAPAN: Dl6Y5 - 130000'1-
U.S.A. : D16Y7, D16YB - 150000'1-
Paint Code
oa
COLOR
G.82P
1300001
A4RA | 4-speed Automatic TransmissionS40 :s-speed Manual TransmissionM4VA I Continuously Variabte
Transmission (CVT)
A4RA : 5000001-
S40 : 1000001-
M4VA: 1000001-
NH-503P
NH-538
NH 583M
R-81
R-95P
Cypress Green Pearl
Granada Black Pearl
Frost White
New Vogue Silver MetallicMilano Red
lsland Coral Pearl
1-4
OO

Chassis and Paint Codes
U.S. 1997 Model (2-door Coupe)
Vehicle ldentification Number
and Federal Motor Vehicle
Safety Standard Certification
OOEngine Number
Engine Typ6
D16Y5: 1600 SOHC VTEC-E 16 vatves
Sequential Multiport
Fuel-injected Engine
D16Y7: 1600 SOHC 16-valves
Sequential Multiport
Fuel-injected EngineDl6Y8r 1600 SOHC VTEC 16 vatves
Sequential Multiport
Fuel-injected Engine
Serial Number
JAPAN: D16Y5 2300001-
U.S.A. : Dl6Y7, Dl6Y8 - 2500001-
Paint Code
D16Y5 - 2300001
eo
COLOR
Lino. Eody and Engine Typ6
EJ6: ClVlC2-door/D16y7
EJ7: ClVlC2-door/Dl6Yb
EJ8: ClVlC2-door/D16y8
Body Type and Transmission Type
Check Digit
Model Yeal
V: 1997
L: East Liberty, Ohio Plant, U.S.A.
A4RA: 4 speed Automatic Transmission84RA : 4-speed Automatic TransmissronS40 :s-speed Manual TransmissionM4VA: Continuously Variable
Transmission (CVT)
A4RA : 6000001-
B4RA: 6000001-
S40 : 1000001-
M4VA: 2000001-
G.82P
NH-503P
NH,538
NH-583M
R-8r
Cypress Green Pearl
Granada Black Pearl
Frost White
New Vogue Silver Metallic
Milano Red
1-1 0
G.82P
lo

Ghassis and Paint Codes
U.S. 1998 Model (2,door Coupel
Vehicle ldentif ication Number
and Federal Motor Vehicle
Safety Standard Certification
lHG EJ6 12*WL 000001
Line, Body and Enginc TypeEJ6: ClVlC2-door/D16y7
EJ7: ClVtC2-door/D16ys
EJ8: ClvlC2-door/D16y8
Body Type and Transmission Type
5: EX with ABS and IVCChock Digir
Model Year
W: 1998
L: East Liberty, Ohio ptant. U.S.A.
eaEngine Number
Engine Type
D16Y5: 1600 SOHC WEC-E l6,vatvesSequential Multiport
Fuel-injected EngineD16Y7: 1600 SOHC 16-valves
Sequential Multiport
Fuel-in.iected EngineDl6Y8: 1600 SOHC WEC 16-vatves
Sequential Multiport
Fuel-injected EngineSerial Number
JAPAN: D16Y5 - 3300OOt-U.S.A. : D16Y7, D'16y8 - 3500001-
Paint Code
D16Y5 3300001
0a
COLOR
G.82P
84RA : 4-speed Automatic TransmissronS40 :s-speedManualTransmission
M4VA: Continuously Variable
Transmission (CVT)
B4RA:7000001-
S40 :1000001-
M4VA: 4000001-
NH-592P
NH-578
NH-583M
R-81
Cypress Green Pearl
Flamenco Black PearlTaffeta White
New Vogue Silver MetalticMilano Red
1-16
aa

Chassis and Paint Codes
Vehicle Grade
2: DX, HX
4: EX
5: EX With ABS, Si
Check Digit
Model Year
X:1999
Factory Code
L: East Liberty, Ohio Plant, U.S.A.Serial Number
Vehicle ldentification Number
and Federal Motor Vehicle
Safety Standard Certification
U.S. 1999 Model (2-door Coupe)
Vehicle ldentification Number
1HG EJ6 12*XL 000001
Manutacturer, Make andType of Vehicle'1HG: HONDA OF AMERTCA
MFG., INC.
HONDA Passenger
vehicle
Line, Body and Engine TypeEJ6: ClVlC2-door/D16y7
EJ7: ClVlC2-door/D16y5
EJ8: ClvlC2-door/D16y8
EM1: CIVIC 2-doorlB'1642
Body Type and Transmission Type1: Coupe/s-speed
Manual
2: Coupe/4-speed Automatic, CVT
Engine Number
Engine Type
81642:'1600 DOHC VTEC 16 vatves
Sequential Multiport
Fuel-injected EngineDl6Y5: 1600 SOHC WEC-E 16 vatves
Sequential Multipon
Fuel injected EngineD16Y7: 1600 SOHC t6-vatves
Sequential Multiport
Fuel,injected EngineD16Y8: 1600 SOHC VTEC 16-vatves
Sequential Multipon
Fuel-injected EngineSerial Numbel
JAPAN: 816A2, Dl6Y5 - 4300001-U.S.A. : D16Y7, D16Y8 - 4SO000t -
Paint Code
aa
ta
COLOR
B4RA : 4-speed Automatic TransmissionS40, S4C: 5-speed Manuat TransmissionM4VA : Continuously Variable
Transmission (CVT)
B4RA : 8000001-
S40, S4C:1000001-
M4VA : 5000001-
B-95P
G-95P
NH-592P
NH-578
NH-583M
R-97
Electron Blue Pearl
Clover Green PearlFlamenco Black Pearl
Taffeta White
New Vogue Silver Metallic
Roma Red
1-22
I
NH.592P
ea

Chassis and Paint Codes
U.S.2000 Model (2-door Coupe)
Vehicle ldentification Number
l HG EJ6 12 *Y1000001
Manufacturer. Make and
Type ol Vehicle'1HG: HONDA OF AMERICA
t\4FG., tNC.
HONDA Passenger
Vehicle
Line, Body and Engine Type
EJ6: ClvlC2-door/Dt6Y7
EJ7: ClVlC2,door/D16y5
EJ8: ClVlC2-door/D16Y8
EM1: CIVIC 2-doorlB1642
Body Type and Transmission Type1 : Coupe/s-speed Manual
2: Coupe/4-speed Automatic, CVTVehicle Grade
2: DX, HX
4: EX
5: EX with ABS, Si
Check Digit
Model Year
Y: 2000
Factory Code
L: East Liberty, Ohio Plant, U.S.A.Serial Number
Vehicle ldentification Number
and Federal Motor Vehicle
Safety Standard Certification
Engine Number
81642, D16Y5: 5300001-
Dl6Y7, Dl6Y8: 5500001-
Engino Type
Bl642; 1600 DOHC WEC '16-vatves
Sequential Multiport Fuel-injected
Engine
D'I6Y5: 1600 SOHC WEC-E 16.vatves
Sequential Multiport Fuel-injectedEngine
D16Y7: 1600 SOHC 16-valves Sequenlal
Multiport Fuel-injected Engine
D16Y8: 1600 SOHC WEC 16-vatves
Sequential Multipon Fuel-injected
Engine
Serial Number
COLOR
D16Y5 - 5300001
ta
to
Paint Code
B4RA : 4-speed Automatic Transmission
S40, S4C: 5-speed Manual Transmissron
M4VA :ContinuouslyVariable
Transmission (CVT)
B4RA : 9000001*
S40. S4C: 1000001-
M4VA :6000001-
B-95P
NH-578
NH.583M
NH-592P
R-81
Electron Blue Pearl
Clover Green Pearl
Taffeta White
New Vogue Silver Metallic
Flamenco Black Pearl
Milano Red
1-28
NH.592P
to

(urbY5, ul6Y7, Dl6Yg enl
MEASUREMENT
Sines) -Section6 -
STANDARD INFWTCompression250 rpm and wide open throftlekPa {kgf/cm,, psi) NominalMinimumMaximum variationWarpageHeight
End play
Camshaft to-holder oil clearanceTotal runoutCam lobe height D16y7
D16Y5
D16Y8
INEXIN
EXIN
EX
Secondary
PrimaryMidSecondary
930 {9.5, 135)200 12 0 ?R\Cylinder head
92.95 - 93.05 {3.659 3.663)0.05 {0.002)
Camshaft0.05,0.15 (0.002 0.006)0.050 - 0.089 (0.002 _ o.oo4)0.03 (0.001)max.
35.299 (1.3897131.241 /.1.4678)38.427 (1.5129)32.193 11 .267 4l38.784 (1.5269)
36.778 (1.4479)
38.274 (1.5068)
37.065 .4592)38.008 (1.4964)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
=
Valve clearanca {Cold)
Valve stem O.D.
Stem-to guide clearance
width
Stem insta ed height
Free lengrh Dt6y7D16Y5
INEXINEXINEX
INEXINEX
INEXINEX
INEXINEX
D16Y8
t.D.
Installed height
0.18 - 0.22 10.007 - 0.009)0.23 0.27 (0.009 0.011)5.48 - 5.49 (0.2157 0.2161)5.45 - 5.46 {0.2146 _ 0.2150}0.02 - 0.05 (0.001 _ o.oo2)0.05-008lono2-nnn?l
5.45 (0.2146)
5.42 tO.213410.08 (0.003)
0.11 (0.004)
1.6 (0.063)
2.0 (0.079)
53.a9 \2.122|j$.a9 Q.122)
Valve seat0.85 - 1.15 (0.033 - 0.045)1.25 - 1.55 10.049 - 0.061i53.17 - 53.64 {2.093 _ 2.112)53.17 - 53.64 (2.093 _ 2.112)Valve spring57 .9 (2.2a)
56.5 \2.22157 .9 t2.29l58.0 (2.2a)
58.7 {2.31iValve guide5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 _ 0.218)17.85 - 18.35 \0.103 - 0.722)18.65 19. t5 (0.734 _ 0.754)
5.55 t0.219)5.5s {0.219)
Rocker armArm-to shaft clearanceINEX0.017 - 0.050 (0.0007 0.0020)0.018 - 0.054 (0.0007 - 0.0021)0.08 (0.003)
0.08 (0.003)
Standards and Service Limits
Cylinder Head/Valve Train (Dt6y5, Dt6y7, D
L,
ra
3-2
LO

Section 7
Unlt of length: rnm ( n)
Engine Block(816A2 engine) -
MEASUREMENT
Warpage of deck surface
Bore diameterBore taperReboring limit
STANOARD {NEW)
0.05 (0.002)
8L00 81.02 (3.189 3.190)
SERVICE LIMIT
0.08 {0.03)81.07 (3.192)
0.05 (0.002)
0.25 (0.01)
Cylinder block
PistonSkin O D. At 15 mm (0.6 in)
{rom bottom of skirt
Clearance in cylinder
Groove width (for ring) ToPSecondoil
80.980 - 80.990 (3.lUUz 3. rUubl du Y/u lJ. ro/o,
I0.010 0.040 (o.ooo4 - 0.0016' 0 05 r0 002) II O3O 1.040 10.0406 - 0.04091 1 060 {0 0417) |1.230 - 1.?40 {0.0484 . 0.04881 1.260 10.04961 1'*: ?:::i?l:91'::ll:l I::::::= lPiston ringRing-to-groove clearance
Ring end gap
o.D.Pin to-piston clearance
Pin'to rod interference
Small end bore diameter
Large end bore diameterEnd play installed on crankshaft
Main journal diameterNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod journal diameterTaperOut of roundEnd play
Total runout
Main bearing to_journal oil clearance
No. 1, 2, 4 and 5 journals
No. 3 journal
Bod bearing'to iournal oil clearance
Second
Top
Secondoil
Nominal
0.13 (0.005)
0.1310.005)0.60 (0.024)
0.60 t0.024)0.7010.028)0.70 (0.028)
,rr]q!4l
-l
u.u45 - u.u/u lu.uu ro
0.040 - 0.065 (0.0016 0.0026)*l
0.045 - 0.070 (0.0018 0.0028)*'
0.20 - 0.35 (0.008 - 0.014)*1
o.20 - 0.30 (0.008 - 0.012)*'
0.40 0.55 (0.016 0.022)
0.20 - 0.50 (0.008 - 0.020)*'
0.20 - 0.45 (0.008 - 0.018)"
20.994 - 21.000 {0.8265 - 0.8268)
0.010 - 0.022 (0.0004 0.0009)
0.013 - 0.032 (0.0005 - 0.0013)
20.968 20.981 (0.8255 - 0.8260)
lliSlto?,o.oou o.o''r, o.rotoo'ut
Piston pin
Connecting rod
54.976 55.000 (2.1644 - 2.1654)
54.970 - 54.994 (2.1642 2.1651)
44.976 - 45.00011.'1707 - 1.1711|
0.005 (0.0002) max.0.004 (0.0002) max.0.10 0.35 (0.004 - 0.014)
0.020 (0.0008imax.
0.010 (0.0004)
0.006 (0.0002)
0.45 (0.018)
0.030 (0.0012)
Crankshaft
Eearing0.024 - 0.042 (0.0009 0.0017)
o.o3o - 0.048 {0.0012 0.0019)
0.032 - 0.050 (0.0013 - 0.0020)
0.06 (0.002)
0.06 (0.002)
0.06 (0.002)
*1: RIKEN manutactured prston rrng*2:TEIKOKU PISTON RING manufactured piston ring
gineslSection 8
(cont'd)
Engine Lubri,cation (Dl6Y5, Dl5Y7' Dl6Y8 enginesl -
MEASUREMENTSTANOARD (NEW) S€RVICE LIMIT
4.3 (4.5, 3.8)Ior engine overhaul
3.6 (3.8, 3.2) for oil change, including filter
3.3 (3.5, 2.9) for oil change, without filter
3.7 (3.9,3.3)for engine overhaul
3.3 (3.5, 2.9) for oil change, including filter
3.0 {3.2, 2.6} for oil change, without filter
0.02 - 0.14 (O.OO1 - 0.006) 0.20 {0 008)
0.10 0.18 (o.oo4 - 0.007) i 0.20 (0 008)
o 03 !.08 (qool!.oo3l _ (0 006) -
70 (0.7, 10) min.
340 (3.5,50) min
Engine oilCapacity | (US qt, lmp qt) D16Y7
D16Y5 D16Y8
lnner-to-outer rotor radial clearance
Pump housing to_outer rotor radialclearance
Pumo housrnq_to rotor a)rial clearance
Pressure setting with oil temperature 176'F (80'Ci
kPa (kgf/cm', PsiI at idleat 3,000 rpm
Oil pump
Relief valve
3-5

MEASUREMENTSTANDARD INFWIEngine oilCapacityf (uS qt, lmp qt)
Inner-to outer rotor radial clearancePump body-to outer rotor radialclearancePump body to-rotor axial clearance
4.8 (5.1, 4.2) for eng;ne overhaul4.0 (4.2, 3.5) for oil change, ;ncludin3.7 (3.9.3 3)for dil .h,nde '^,irh^,,rg oilfilter
Oil pump0.04 - 0.16 {0.002 - 0.006)0.10 - 0.19 (0.004-0.007)0.02 0.07 10.001 ,0.003)
0.20 (0.008)
0.20 {0.008)0 15 {O OO6iRelief valvePressure setting 176"F (80.C)kPa (kgflcm,, psi) at;dteat 3,000 rpm70 (0.7, 10) min.340 (3.5,50) min.
Standards and Service Limits
Engine Lubrication (B16A2 engine) (cont,d) - Section 8
Cooling - Section 10
L,
L.
MEASUREMENTSTANOARO {NEW)RadratorCoolant capacity t 1US qt, tmp qt)including engine, heater, cooling line andreservotr
Beservoir capacity:0.4 f {0.42 US qt, 0.35 lmp qt)
81642 engine5.0 {5.3, 4.4) for overhaul4.5 (4.8, 4.0) for cootant changeD16Y5, D16Y7, D16Y8 engines:M/T: 4.2 (4.4, 3.7)for overhaul3.1 (3.3, 2.7) for coolant changeA"/T: 016Y74.1 (4.3, 3.6) for overhaul3.0 (3.2, 2.6) for cootant changeDl6Y84.3 {4.5, 3.8)for overhaul3.2 (3.3, 2.8) for cootant changeCW: 4.3 (4.5,3.8)for overhaul3.2 (3.3, 2.8)for cootant chanqeRadiator capOpeningpressure kPa(kgl/cm,,psi)
Start to open .F (.C)Fully open "F ('C)Valve lift at fulty open
93 123 (0.95- 1.25, 14 18)
169 - 176 (76 80)194 (90)
8.0 (0.31)min.
196 - 203 191 95)Subtract 5 - 15 {3 - 8) from actual ,,ON,, temperature
Thermostat
Cooling fanThermoswilch 'ON" temperature F r.C,Thermoswitch "OFF' lemperature .F ( C)
L
3-6
L,

Unit of length: mm (in)
Fuel and Emission - Section
MEASUREMENTSTANOARO (NEW)
260 310 (2.7 - 3.2, 38 - 46)
260 - 310 (2.7 - 3.2, 38 - 46i
260 - 310 (2.7 - 3.2, 38 - 46)
210 - 320 Q.A - 3.3, 40 - 47 1
45 {11.9, 9.9)
M/T (neutral) I A/T or C\.T (lE or fd positioni
Fuel paessure
regulator
Pressure wilh fuel pressure regulator vacuum hose
disconnected kPa (kgvcm', Psi)D16Y5D 16Y7D16Y881642
FueltankCapacity I (US gal, lmp gal)
E ngineldle speed rpm
016Y5D16Y7D16Y8816A2
u.s.A.CanadaU,S,A.Canada
670 1 506701 50670150700 t 50
7501 507501 507501 50
700 t 50700 I 507001 50750150750 r 50
ldle CO %0.1 max.
Clutch - Serrtion 12
MEASUREMENTSTANDARD {NEWI I SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal play
Disengagement height to floorto carpet
16s (6 1/2)130 140 (5 1/8 5 1/2)
12 -21 t1l2 - 13/16183 (3 1/4)44 (1 3/4) min. Reference
FlywheelClutch surface ruoout
Rivet head depthThickness
0.05 (0.002) max.0.15 (0.006)
Clutch disc1.3- 1.9 (0.05 - 0.07)
8.5 - 9.1 (0.33 - 0.36)
0.2 {0.01)5.5 (0.22)
Pressure plateWarpageDiaphragm spring fingers alignment
0.03 (0.001) max0.6 (0.02) max
0.15 (0.006)
1.0 (0.04)
Lro
3-7
lfllHlllllllllrltllli[

Design Specifications
ITEMMETRICENGLISHNOTEDII/IENSIONS Overall Length2 door Coupe/4 door Sedan (,96 98)('99,'00)2 door Hatchback (,96, ,97)
('98 - 00)OverallwidthOverall height 2 door Coupe/2 door Hatchback4-door SedanWheelbase
I Track FronvRearGround ClearanceSeatiog Capacity
4,445 mm4,450 mm4,170 mm4,180 mm1,705 mm1,375 mm1,390 mm2,620 mm1,475/1,415 mm150 mm
175.0 in115.2 in164.2 in164.6 in67.1 in54.1 in54.7 in103.1 in58.1/58.15.9 in
WEIGHT (USA)Gross Vehicle Weight Raring (GVWR)2 door Coupe HX M/T, DX M/THX CVI ('96)HX CVT ('97,'98)HX CVT ('99}DX A,/T (96 98,DX A"/T ('99, '00)
EXSi2 door Hatchbacl CX. DX r'96, 97,cx, DX ('98)cx (,99, ,00)
DXM/Ti'99,00iDX A/T ( 99, 00,4 door Sedan DX, LX, DX-VEX
3,290 tbs3,320 tbs3,330 tbs3,360 rbs3,290 rbs3,310 tbs3,440 tbs3,480 tbs3,285 tbs3,290 tbs3,290 tbs3,290 tbs3,330lbs3,330 tbs3,460 tbsWEIGHT (CANADA)Gross Vehicle Weight Bating (GVWR)2-door Coupe DX ('96)DX ('97 00)DX-Gsi 1,96)si ('97 - 00)siR2 door Hatchback CX, CX,G ('96)cx, cx,G 1,97)cx-G (,98)
cx ('98 00)DX M/T, SE M/IDX A,/T, SE A,/T4 door Sedan LX, LX VEX M/IEX A/T
1,500 ks1,510 kg1,510 kg1,560 kg1,570 kg1,590 ks1,495 kg1,505 kg1,510 ks1,510 ks1,510 kg1,530 kg1,510 kg1,510 ks1,540 ksENGINEType
Cylinder ArrangementBore and Stroke D16Y5, D16Y7, Dt6y8B 1642DisplacementD16Y5, D16Y7, Dl6Y881642Compression Ratio D16Y5, D16y7D16Y8816A2Valve TrainLubrication SystemOil Pump Displacement at 6,800 engine rprnD16Y5, D,l6Y7, D16Y881642Water Pump Displacementat 6,000 engine rpm 016Y5, D16Y7, D16y8816A2Fuel Required D16Y5, D16Y7, D16y8
816A2
Water-cooled, 4-stroke SOHC*1, SOHCVTEC"', SOHC WEC.E'3, DOHC VTEC{gasoline engineInline 4 cylinder, transverse2.95 x 3.54 in3.19 x 3.05 in97.0 cu-in97.3 cu in9.49.610.2Belt driven, 4 valve per cylinderForced and wet sump, trochoid pump
33.4 f (35.3 US qt, 29.4 lmp qt)/minute43.8 | (46.3 US qt, 38.6 lmp qt)/minute
125 { {132 US qt, 110 lmp qt}/minute140 f {148 US qt, 123 lmp qt}/minuteUNLEADED gasoline with 86 PumpOctane Number or higherPremium UNLEADED gasoline 91 PumpOctane Number or higher
75.0 x 90.0 mm81.0 x 77.4 mm1,590 cm31,595 cm3
*1: D16Y7*': D16Y8*3: D16Y5*': 816A2
STARTEBType/MakeNormal OutputNominalVohageHour RatingDirection of Rotation
Gear reduction/MITSUBA1.0 kw, 1.2 kw12V30 secondsClockwise as viewed from gear end
5-Z.V
-