Pin out HONDA CIVIC 1998 6.G User Guide

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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Piston RingsCrankshaft Oil Seal
Alignment (cont'dl
TOP RING ---.>
SECOND RING >
MARK
,a-)
/\_4
o,.r^o( qffi<--sPACER
\Z-.
v
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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Oil Pump
Overhaul
NOTE:
. Use new O rings when reassembllng.
. Apply oil to O-rings before installation.
. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003
. The rotors must be installed to the same direction in order'
o After reassembly, check that the rolors move without binding'
B15A2 engine:
6x1.0mm7 N.m (0.7 kgf m, 5 lbf ft)
OUTER ROTORInspection, page 8-13
INNER ROTORpage 8-13
OOWELPIN
O-RINGReplace.
6x1.0mm11 N.m (1.1
8 tbtfrlkgf.m,
PUMP HOUSINGInspection, page 8-13
Apply liquid gasket
to the mating surface of
the cylinder blockwhen installing.
8 x 1.25 mm24 N,m {2.i1 kgl.m.
17 tbf.ft)RELIEF VALVEValve mlst slide freeiy
in housing bore.Replace if scored.OIL SEALReplace.lnstallation,page 8-14
SEALING BOLT39 N.m l4O kgt'm,29 tbt frl
\(cont'd)
SPRING
8-11

Oil Pump
Overhaul (cont'dl
NOIE:
. Use new O rings when reassembling.. Apply oil to O rings before instalraUon.. Use liquid gasket, Parr No. 08718 - 0001 or08718_0003.. The rotors must be installed to the same direction.. After reassembly, check that the rotors move without binding.
D16Y5, D16Y7, D16Y8 engines:
(
6x1.0mm7 N.m (0.7 kgI.m, 5 lbf ftl
PUMP HOUSINGInspection, page 8 13Apply liquid gasketto mating surface ofthe cylinder biockwhen installing.
INNER ROTORInspectron, page 8 13
DOWEL PIN
PUMP COVEB
O-RING
_.feor,""
\6x1.0mm11 N.m {1.1 kgf.m,8lbl.ft)RELIEF VALVEValve must slide freelyin housing bore.Replace if scored
OIL SEAL
[".?li;:;"". *,", ,.rg
""rc
@.-*or"."
9''ggttt*
8-12

4.
Removal/lnspection/lnstallation
2.
3.
1.
5.
6.
1.
8.
Drain the engine oil.
Turn the crankshaft and align the white groove on
the crankshaft pulley with the pointer on the lower
cover.
Remove the cylinder head cover and upper cover'
Remove the power steering pump belt, air condi-
tioner beit and the alternator belt
Remove the crankshaft pulley and remove the lower
cover.
Remove the timing belt.
Remove the drive pulley.
Remove the oil pan and oil screen.
O.RINGReplaceOOWEL PIN
OIL SCREEN
9. Remove the oil PumP.
!'a
10.Remove the screws from the pump housing, then
separate the housing and cover'
Check the inner-to-outer rotor radial clearance on
the pump rotor. lf the inner-to outer rotor clearance
exceeds the service limit, replace the inner and
outer rotors.
lnner Rotor-to-Outer Rotor Radial Clearance
Standard {New}: 815A2 engine 0.04 - 0.16 mm
(0 002 - 0'006 in)
D16Y5, D16Y7, D16Y8 engines
0.02 - 0.14 mm 10.001 - 0.006 in)
Service Limit: 0.20 mm (0 008 inl
OUTER ROTOR
INNER ROTOR
Check the housing-to-rotor axial clearance on the
pump rotor. lf the housing-to rotor axial clearance
exceeds the service limit, replace the set of inner
and outer rotors and/or the pump housing
Housing-to-Rotor Axial Clearance
Standard (N€w): 816A2 engine 0.02 - 0.07 mm
(0.001 - 0.003 inl
D16Y5, D16Y7, D16Y8 engines
0.03 - 0.08 mm (0.001 - 0.003 inl
S€rvice Limit: 0.15 mm 10.006 in)
11.
't2.
(cont'd)
8-13

Oil Pump
RemovaUlnspection/lnstallation (cont'dl
13. Check the housing-to-outer rotor radial clearance.lf the housing-to-outer rotor radial clearanceexceeds the service limit, replace the set of innerand outer rotors and/or the pump housing.
Housing-to-Outer Rotor Badial Clearanco:Standard {Newl: 816A2 sngine 0.10 - 0.19 mm(0.004 - 0.007 in)
D16y5, Di6y7, Dt6y8 engines0.10 - 0.18 mm {0.00it _ 0.007 in)Service Limit: 0.20 mm (0.008 in)
lnspect both rotors and pump housing for scoringor other damage. Replace parts if necessary.
Remove the old oil sealfrom the oil pump.
Using the special tool, gently tap in the new oil sealuntil the driver bottoms against the pump.
NOTE: The oil seal alone can be replaced withoutremoving the oil pump.
DRIVER ATT52x55mm077a6 - 0010ao0
14.
15.
16.
8-14
PUMP HOUSING
17. Reassemble the oil pump, applying thread lock tothe pump housing screws.
18. Check that the oil pump turns freely.
19. Apply a light coat of oilto the seal lip.
20. Install the two dowel pins and new O-ring on the oilpump.
21. Apply liquid gasket to the cylinder block mating sur_face of the oil pump.
NOTE:
. Use liquid gasket, Part No.08718 - oOOj or 08718- 0003.. Check that the mating surfaces are clean and drybefore applying liquid gaskel. Apply liquid gasket evenly, in a narrow bead cen-tered on the mating surface.o To prevent leakage of oil, apply liquid gasket tothe inner threads of the bolt holes.. Do not install the parts if five mtnures or morehave elapsed since applying liquid gasket.Instead. reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
81642 engine:
\
D16Y5, D16Y7, D16Y8 engines:
along the broken line.

Glutch Master Gylinder
IRemovaUlnstallation
CAU'NON:
. Do not sDill brake lluid onthevehicle;it may damage
the paint; if brake fluid does contact the paint, wash
it off immediatelY with water.
. Plug the end ofthe clutch line and reservoir hos€ with
a shop towelto prevent brake tluid from coming out
1. The brake tluid can be removed from the clutch
master cylinder reservoir with a syringe
2. Disconnect the clutch line and reservoir hose from
the clutch master cylinder.
19N.m 11.9 kgf.m,14 tbf.ttl
[.
3. Pry out the lock pin, and pull the pedal pin out
the yoke. Remove the nuts
NUTS8 x 1 .25 mm13 N.m {'1.3 kgt.m,9.4lbf ft)
)
of
CLUTCH LINE
iffi,
4. Remove the clutch master cylinder.
CLUTCH MASTER CYLINDER
lnstall the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system {see page
12-61,
12-5

Transmission Assembly
Removal(cont'd)
17. Remove the three upper transmission mounting
bolts and the lower starter mounting bolt,
STARTERMOUNTINGBOLT10 x 1.25 mm44 N.m (4.5 kgf.m,33 rbnftl
TRANSMISSIONMOUI{TING EOLTS12 x 1.25 mm& N.m (6.5 kgt'm,47 lbl.ftl
18. Remove the rear mount bracket bolts and transmis-
sion mounting bolts.
12 x 1.25 mm64 N.ft 16.5 kgl.m,47 lbl.ftl
SPECIAL BOLTReplace.'ll x 1.5 mm84 N.m (8.5 kgf.m, 61 lbf.ftl
SPECIAL BOLTReplace.14 x 1,5 mln84 N.m (8.5 kgl.m, 61
WASI{ERREARMOUNTBRACKET
rbl.ftt
Pull the transmission away from the engine until it
clears the mainshaft. then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.
1(|
Installation
Install the transmission assembly in the reverse order of
removal.
Before installing, check that the two dowel pins are
installed in the clutch housing.
When installing the starter cable, make sure that the
crimped side of the ring terminal is facing out (see
section 23).
Apply grease to the parts as shown, then install the
release fork and release bearing,
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
RELEASE FORK BOLT12 x 1.25 mm29 N'm 13.0 kgt,m,(P/N 08798-90021
22 tbl.ttlR€LEASEBEARING
J
RELEASEFORK8()07
ra
{PiN 08798-9002)
tP/N 08798-900210.3-0.9 g
10.01-0.03 ozl

Mainshaft Thrust ShimI
I
Adjustment (cont'dl
b.Attach the mainshaft holder to the mainshaft asfollows:
NOTEI
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip istoward the transmission.
. Align the mainshaft holder's lip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSIIAFTHOLDER07GAJ-PG20110
d.
Seat the mainshaft fully by tapping on the end witha plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
u
e. Zero a dial gauge on the end ofthe mainshaft.
MAINSHAFT HOLDER07cAJ_PG20110
Turn the mainshaft holder bolt clockwise: stop turn,ing when the dial gange has reached its maximummovement. The reading on the dial gauge is theamount of mainshaft end olav.
CAUTION: Turning the mainshaft holder bolt morethan 60 degre€s after the needle ot the dial gauge
stops moving may damage the iransmission.
lf the reading is within the standard. the clearance iscorrecl.
lf the reading is not within the standard, recheck theshim thickness.
Standard: 0.11 - 0.18 mm {0.00it - 0.007 in}
t.
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