Part number HONDA CIVIC 1997 6.G Workshop Manual

Rocker Arms
Disassembly/Reassembly
CAUTION: After installing the rocker shaft oritice, make suro thot the orifics is correctly installed in the hole of rockershaft by trying to turn the rocker shaft. ll the orifice is in place, it should not turn.
NOTE:
. ldentify parts as they are removed to ensure reinstallation in original locations.. Inspect rockershafts and rockerarms (see page6-73).
o Rocker arms must be installed in the same position if reused.. Clean the rocker shaft orifices when installino.
a
I erior. to ,"installing, clean arr the parts in sorvent, dry them, and appry rubricant to any contact surfaces.
y'///
CYLTNDER NUMBER
SEALING BOLTS 20 mm64 N m {6.5 kg{.m, /t7 lbf.ftl
k
r ROCKEN
INTAKE ROCKER ARM ASSEMBLIES

Connecting Rod Bearings
Clearance
Remove the connecting rod cap and bearing half
Clean the crankshaft rod iournal and bearing half
with a clean shop towel.
Place plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the nuts.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and bearing half and measure
the widest part of the plastigage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engine:
Standard lNewl: 0.032 - 0.050 mm
10.0013 - 0.0020 in)
Service Limit: 0.06 mm 10.002 inl
D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 0.020 - 0.038 mm
(0.0008 - 0.0015 in)
Service Limit 0.05 mm 10.002 inl
'1.
4.
lf the plastigage measures too wide or too narrow'
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown in the right column), and
recheck the clearance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf the plastigage shows the clearance is still incorrect.
try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.
NOTE: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
PLASTIGAGE STRIP
\
7.
7-11
Selection
CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not sclub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the side of each con
necting rod as a code for the size of the big end Use
them, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearlngs
Half of number ls
stamped on bearingcap and the otherhalf is stamped onrod.
Bearing ldentilication
Color code is on theedge ofthe bearing.
lfA--;T] |
lle"'tt l;llcorlll ll
I lD;;ilril |l-l
Larger brg end bore
Smaller Smallerrod bearlngjournal (thicker)
---------------- Smallerbearing{thrcker)
RedPinkGreen
PinkGreen
GreenErownBlack
GreenBrownBlackBlue
1234
Connecting Rod Journal Code Locations (Lettels)

Oil Seals
lnstallation
NOTE:
. Engine removal is not required.
. The crankshaft oil seal housing should be dry.
Apply a light coat of grease to the crankshaft and to
the lips of the seals.
1. Using the special tool, drive in the timing pulley-
end seal until the driver bottoms against the oil
pump.
When the seal is in place, clean any excess grease
off the crankshaft and check that the oil seal lip is
not distorted.
07947 -S800200
lnstall seal with thepart number sadefacing out.
I
2. Measure the flvwheel-end seal thickness and the oil
seal housing depth. Using the special tool. drive the
flywheel-end seal into the rear cover to the point
where the clearance between the bottom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.02 -
0.03 in) (see page 7-23).
NOTE: Align the hole in the driver attachment with
the Din on the crankshaft.
DRIVER ATTACHMENT0794a-s800101lnslall seal with thepart number sidefacing out.
DRIVER07749-0010000
7 -29

7. lf the clearance is more than the standard, select a
new thrust shim from the following table
NOTE: It the clearance measured in step 6 is within
the standard. go to step 10.
Standard: 0 - 0.10 mm l0 - 0.00/t inl
72 mm THRUST SHIM: D16Y7 engin€
\
Part NumberThickness
41441 - PL3 - A001.0 mm (0.0394 in)
41442-PL3-A00'1 .1 mm {0.0433 in)
41443-PL3-A001.2 mm {0.0472 in)
41444-PL3-A001.3 mm (0.0512 in)
41445-PL3-A001.4 mm (0.0551 in)
41446-PL3-A001.5 mm (0.0591 in)
41447-PL3-A001.6 mm (0.0630 in)
41448-PL3-A001.7 mm (0.0669 in)
4r449-PL3-A001.8 mm (0.0709 in)
41450-PL3-A001.05 mm {0.0413 in)
41451-PL3-A001.15 mm (0.0453 in)
41452-PL3-A001.25 mm (0.0492 in)
41453-PL3-A001.35 mm (0.0532 in)
41454-PL3-A00'1.45 mm (0.057'l in)
41455-PL3-A001.55 mm (0.0610 in)
41456-PL3-A001.65 mm (0.0650 in)
41457-PL3-A001.75 mm (0.0689 in)
80 mm THBUST SHIM: D16Y5. D16Y8 engines
Remove the bolts and transmission housing.
Replace the thrust shim selected in step 7, then
recheck the clearance.
Remove the bolts and transmission housing. Apply
liquid gasket to the surface of the transmission
housing and reassemble
8.
9.
10.
Part NumbelThickness
41441 - PL3 - B001.0 mm (0.0394 in)
41442-PL3-8001.1 mm (0.0433 in)
41443-PL3-8001.2 mm (0.0472 in)
41444-PL3-8001.3 mm (0.0512 inl
41445-PL3-8001.4 mm (0.0551 in)
41446-PL3-8001.5 mm (0.0591In)
41447-PL3-8001.6 mm (0.0630 in)
4r 448 - PL3 - 8001.7 mm (0.0669 in)
4 t449 - PL3 - 8001.8 mm (0.0709 in)
41450-PL3-800'1.05 mm (0.0413 in)
41451 - PL3 - 800'1.15 mm (0.0453 in)
41452-PL3-8001.25 mm (0.0492 in)
41453-PL3-B001.35 mm (0.0532 in)
41454-PL3-B001.45 mm (0.0571 in)
41455-PL3-B001.55 mm (0.0610 in)
41456-PL3-8001.65 mm (0.0650 in)
41457-PL3-8001.75 mm {0.0689 in)

70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s
Part NumberThickness
23931 - PL3 - 8000.60 mm 10.0236 in)
23932-PL3-8000.63 mm (0.0284 in)
c23933-PL3-8000.66 mm (0.0260 in)
D23334-PL3-8000.69 mm 10.0272 in)
E23935-PL3-8000.72 mm (0.0283 in)
F23936 - PL3 8000.75 mm (0.0295 in)
23937-PL3-B000.78 mm (0.0307 in)
23938-PL3-8000.81 mm (0.0319 inl
23939-PL3-8000.84 mm (0.0331 in)
23940-PL3-8000.87 mm {0.0343 in)
23941 - PL3 - 8000.90 mm (0.0354 in)
L23942-PL3-8000.93 mm (0.0366 in)
23943-PL3-8000.96 mm (0.0378 in)
N23944-PL3-8000.99 mm i0.0390 in)
o2394s-PL3-8001.02 mm (0.0102 in)
P23946-PL3-8001.05 mm {0.0413 in}
o23947-PL3-8001.08 mm (0.0{25 in)
23948 - PL3 800'1.1'1 mm (0.0437 4n)
23949-PL3-8001.14 mm (0.0449 inl
T23950-PL3-8001.17 mm (0.0461 in)
23951 - PL3 - 8001.20 mm (0.0472 in)
23952-PL3-8001.23 mm (0.0444 in)
239s3-PL3-8001.26 mm {0.0496 in)
X23954-PL3-8001.29 mm (0.0508 in)
2395s-PL3-8001.32 mm (0.0520 in)
z23956-PL3-8001.35 mm (0.0531 in)
23957-PL3-8001.38 mm (0.0543 in)
A823958-PL3-8001.41 mm (0.0555 in)
AC23959-PL3-8001.44 mm {0.0567 in)
AD23960-PL3-8001.47 mm (0.0579 in)
2396't-PL3-8001.50 mm (0.0591 in)
23962-PL3-8001.53 mm (0.0602 in)
AG23963-PL3-8001.56 mm (0.0614 in)
AH23964-PL3-8001.59 mm (0.0626 in)
23965-PL3-8001,62 mm (0.0638 in)
23966-PL3-8001.65 mm (0.0650 in)
AK23967-PL3-8001.68 mm (0.0661 in)
23968-PL3-8001.71 mm (0.0673 in)
23969-PL3-8001.74 mm (0.0685 in)
AN23970-PL3-8001.77 mm (0.0697 in)
AO23971- PL3 8001.80 mm (0.0709 inl
6. Installthe oil guide plate and selected thrust shim in
ths transmission housing
NOTE:
. Clean the thrust washer, spring washel and
thrust shim thoroughly belore installation.
. lnstall the thrust washer, spring washer and
thrust shim proPerlY.
THRUST SHIM
I
OIL GUIDEPLATE
TRANSMISSIONHOUSING
8.
o
10.
7, Install the thrust washer and spring washer in the
mainshaft.
lnstall the mainshaft in the clutch housing
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
Check the thrust clearance in the manner doscribsd
below.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Slide the mainshaft base and the collar over the
mainshaft.
CLUTCHHOUSING
11.
lz.
MAITISHAFT BASE07GAJ-PG20130COLLAF07GAJ -PG20120
{cont'd}
13-37
THRUST WASHER
SPRING WASI{ER

Change Holder Assembly
Clearance Inspection (cont'd)
7. Measure the clearance between the select arm andthe 10 mm shim.
Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in)
lf the clearance is not within the standard, selectand install the appropriate l0 mm shim for the cor-rect clearance from the chart below.
mm Shim
8.
SELECT ARM
l0 mm SHIM
Part NumberThickness
24435-689-0000.8 mm (0.031 in)
B24436-589-0001.0 mm (0.039 in)
c24437-689-0001.2 mm (0.047 in)
D24438-689-0001.4 mm (0.055 in)
E24439-689-0001.6 mm {0.063 in)
13-60
I
9. Measure the clearance between the shift arm holderand the change piece.
Standard; 0.05 - 0.35 (0.fi)2 - 0.014 inlService Limit: 0.8 mm (0.03 in)
lf the clearance is more than the service limit. mea_sure the groove of the change piece.
Standard: 12.05 - 12.15 mm {0.i[7it4 - 0.47txt inl
lf the groove is not within the standard, replacethe change piece with a new one.lf the groove is within the standard, replace theshift arm holder with a new one.
vo
SHIFT ARM HOLOER
CHANGE PIECE

t
7. lf the clearance is not within the standard, select a
new 80 mm shim from the following table.
Standard: 0 - 0.10 mm (0 - 0.004 inl
80 mm Shim
Part NumberThickn6ss
41441 - PL3 - 800'1.0 mm (0.0394 in)
B41442-PL3-B001.1 mm (0.0433 in)
c41443-PL3-8001.2 mm (0.0472 in)
D41444-PL3-8001.3 mm (0.0512 in)
41445-PL3-8001.4 mm (0.0551 in)
41446-PL3-8001.5 mm (0.0591 in)
41447-PL3-8001.6 mm (0.0630 in)
H41448-PL3-8001.7 mm (0.0669 in)
41449-PL3-8001.8 mm (0.0709 in)
K41450-PL3-B001.05 mm (0.0413 in)
41451 - PL3 - 8001.'15 mm (0.0453 in)
IV41452-PL3-8001.25 mm (0.0492 in)
N41453-PL3-B001.35 mm (0.0532 inl
P41454-PL3-8001.45 mm (0.0571 in)
41455-PL3-8001.55 mm (0.0610 in)
R41456-PL3-8001.65 mm (0.0650 inl
41457-PL3-8001.75 mm (0.0689 in)
NOTE; lf the clearance measured in step 6 is within
the standard, it is not necessary to 9o to step 9.
13-85
8.Remove the bolts and transmission housing.
Beplace the 80 mm shim selected in step 7, then
recheck the clearance.
Reassemble the transmission and install the trans-
mission housing.
10.

72 mm Thrust Shim
t
Part NumberThickness
23931 - P21 0000.60 mm {0.0236 in}
23932-P21 -0000.63 mm 10.0248 in)
c23933 P21 - 0000.66 mm (0.0260 in)
D23934 - P21 0000.69 mm (0.0272 in)
E2393s-P21-0000.72 mm (0.0283 in)
F23936-P21 -0000.75 mm (0.0295 in)
G23937 -P21-O000.78 mm (0.0307 in)
23938-P21 -0000.81 mm (0.0319 in)
23939-P21 -0000.84 mm (0.0331 in)
J23940-P21 -0000.87 mm (0.0343 in)
K23941 P21 - 0000.90 mm (0.0354 ini
L23942 - P21 0000.93 mm (0.0366 in)
23943-P21 -0000.96 mm 10.0378 in)
N23944 - P21 -0000.99 mm (0.0390 in)
o23945 - P21 0001.02 mm (0.0402 in)
P23946 - P21 0001.05 mm (0.0413 in)
o23947 - P2l 0001.08 mm (0.0425 in)
R23948-P21 -0001.'1 'l mm (0.0437 in)
S23949 - P21 0001.14 mm (0.0449 in)
T23950 - P21 0001.17 mm (0.0461 in)
23951 - P21 -0001.20 mm (0.0472 in)
23952 - P21 -0001.23 mm (0.0484 in)
23953-P21 -0001.26 mm (0.0496 in)
X23954-P21 -0001.29 mm (0.0508 in)
23955 - P21 -0001.32 mm (0.0520 in)
z23956-P21 -0001.35 mm (0.0531 in)
23957-P21 -0001.38 mm 10.0543 in)
AB23958 - P21 -0001.41 mm (0.0555 in)
AC23959 P21 - 0001.44 mm {0.0567 in)
23960 - P21 0001.47 mm (0.0579 in)
AE23961 - P21 -0001.50 mm {0.0591 in)
23962 P21 - 0001.53 mm {0.0602 in)
AG23963-P21 -0001.56 mm (0.0611in)
AH23964-P21 -0001.59 mm {0.0626 in)
23965-P21 -000'1.62 mm {0.0638 in)
23965-P21 - 0001.65 mm (0.0650 in)
AK23967-P21 -0001.68 mm {0.0661 in)
23968 - P21 -0001.71 mm 10.0673 in)
23969 P21 - 0001.74 mm {0.0685 in)
AN23970-P21 -0001.77 mm {0.0697 in)
AO23971 - P21 -0001.80 mm (0.0709 in)
7. lnstallthe thrust shim selected and oil guide plate in
the transmission housing.
72 mm THRUSTOIL GUIDE PLATE
TRANSMISSIONHOUSING
8. Install the spring washer and washer on the ball
beaflng.
NOTE:
. Clean the spring washer, washer and thrust shim
throughly before installation.
. Install the spring washer, washer and thrust
shim properlY.
-WASH€R-<]>-.-'
x -sPRtNG WASHER
-.-sK((9r'
lnstallthe mainshaft in the clutch housing.
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
8 x 1.25 mm
27 N.m (2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
(cont'd)
9.
10.
'I l.
12.
13-89

Mainshaft
Inspection (cont'd)
5.lf the clearance is out of tolerance, remove thethrust washer and measure the thickness.
THRUST WASHER
6. Select and install a new washer, then recheck.
THRUST WASHER 36.5 x 55 mm
After replacing the thrust washer, make sure theclearance is within tolerance.
7.
No.Part NumberThickness
190441 - P4P - 0104.00 mm (0.157 in)
90442-P4P-0104.05 mm (0.159 in)
90443-P4P-0104.10 mm (0.'161 in)
490444-P4P-0104.15 mm (0.163 in)
90445-P4P-0104.20 mm (0.165 in)
90446-P4P-0104.25 mm (0.167 in)
790447-P4P-0104.30 mm (0.169 in)
890448-P4P-0104.35 mm (0.171 in)
90449-P4P-0104.40 mm (0.173 in)
1090450-P4P-0004.45 mm (0.175 in)
b
14-150

13. Measure the clearance between the clutch end plate
and top disc with a dial indicator' Zero the dial indi-
cator with the clutch end plate lowered and lift it up
to the snap ring. The distance that the clutch end
plate moves is the clearance between the clutch end
plate and top disc.
NOTE| Take measurements in at least three places,
and use the average as the actual clearance.
Clutch End Plste-to-Top Disc Clearance:
OIAL INDICATOR
CLUTCH ENDPLATEClearance
14.
CLUTCH DISC
lf the clearance is not within the service limits,
select a new clutch end plate from the following
table.
NOTE: lf the thickest clutch end plate is installed,
but the clearance is still over the standard, replace
the clutch discs and clutch plates.
PLATE NUMBERThickn6ss
ClutchSerYice Limit
1st
2nd
3rd
4th
0.65 - 0.85 mm (0.026 - 0.033 in)
0.65 - 0.85 mm (0.026 - 0.033 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
CLUTCH ENO PLATE
14-165
Plate No.Part NumberThickness
,l
2
J
4
5
6
1
8q
22551 - P4R - 003
22552-P4R-003
22553-P4R-003
22554-P4R-003
22555-P4R-003
22556-P4R-003
22557 -P4B-OO3
22558-P4R-003
22559-P4R-003
2.1 mm (0.083 in)
2.2 mm (0.087 in)
2.3 mm (0.091 in)
2.4 mm (0.094 in)
2.5 mm (0.098 in)
2.6 mm (0.102 in)
2.7 mm {0.106 in)
2.8 mm {0.110 in)
2,9 mm (0.1 '14 in)
CLUTCH END PLATE
A4RA, g4RA Transmission:
M,IRA Transmi$ion:
15. After replacing the clutch end plate. make sure that
the clearance is within tolerance.
Plate No.Part NumberThickness
1
3
'l
.'q
10
11't2
13
14
15'16
17
18
22551 - PCg - 000
22552-PCg-000
22553-PCg-000
22554-PCg-000
22555-PCg-000
22555-PCg-000
22557-PCg-000
22558-PCg-000
22559-PCg-000
22560-PCg-000
22561 - PCg - 000
22562-PCg-000
22563-PCg-000
22574 - P4V - 003
22561 - P4V - 003
22562- P4V - 003
22563-P4V-003
22564-P4V-003
2.4 mm (0.094 in)
2.5 mm (0.098 in)
2.6 mm {0.102 in)
2.7 mm (0.106 in)
2.8 mm (0.110 in)
2.9 mm (0.114 in)
3.0 mm {0.118 in)
3.1 mm (0.122 in)
3.2 mm (0.126 in)
3.3 mm (0.130 in)
2.1 mm (0.082 in)
2.2 mm {0.086 in)
2.3 mm (0.090 in)
3.4 mm (0.134 in)
3.5 mm (0.138 in)
3.6 mm (0.142 in)
3.7 mm (0.146 in)
3.8 mm (0.150 in)