blue HONDA CIVIC 1998 6.G User Guide

Cylinder HeadValve Seats
Warpage
NOTE: lf the camshaft-to-holder oil clearances (see
page 6-36) are not within specification, the cylinder head
cannot be resurfaced.
lf the camshaft-to-holder oil clearances are within sDeci,
fications, check the cylinder head lor warpage.
lf warpage is less than 0.05 mm (0.002 in), cylin-
der head resurfacing is not required.
lf warpage is between 0.05 mm (0.002 in) and
0.2 mm {0.008 in), resurface the cylinder head.
Maximum resurface limit is 0,2 mm (0.008 in)
based on a height of 93 mm (3.66 in).
Measure along edges, and three ways across center.
Cylinder Head Height:
Standard {Newl: 92.95 - 93.05 mm
{3.659 - 3.66:} in)
6-40
\
Reconditioning
'1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf the guides are worn (see page 6-39).
replace them (see page 6-41) belore cutting the
valve seats.
VALVE SEATCUTTER(Commercially available)
2.
?
4.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutter
and the lower edge of the seat with the 60' cutter.
Check the width of the seat and adjust accordingly.
Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard (N€w):
Intake: 0.85 - 1.15 mm 10.033 - 0.045 in)
Exhaust: 1.25 - 1.55 mm {0.049 - 0.061 in}
Sorvice Limit:
Intake: 1.6 mm (0.063 inl
Exhausl: 2.0 mm (0.079 in)
Seat Width
5. After resurfacing the seat, inspect for even valve
seatingr Apply Prussian Blue compound to the
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against
the seat several times.

Valve Guides
7.
VALVESEAT
PFUSSIAN BTUE COMPOUNO
The actual valve seating surface. as shown by the
blue comDound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 60'cutter to
move it down, then one more cut with the 45'
cutter to restore seat width,
. lf it is too low (closer to the vslve edge), you
must make a second cut with the 30" cutter to
move it uD, then one more cut with the 45'cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45" cutter.
lnsert the intake and exhaust valves in the head and
measure the valve stem installed height.
Intake. Exhau3t Siem Installsd Height:
Standard (New): 53.17 - 53.6,4 mm
12.093 - 2.112 in)
Sorvice Limit: 53.89 mm (2.122 in)
lf the valve stem installed height is over the service
limit. reDlace the valve and recheck. lf its still over
the service limit, replace the cylinder head; the
valve seat in the head is too deep.
VALVE STEMINSTALLED HEIGHT
8.
\-
Replacement
1.As illustrated below, use a commercially-available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. In most cases.
the same procedure can be done using the special
tool and a conventional hammer.
VALVE GUIDE DRIVERlCommerciallv available)5.3 mm
87 mm +- 57 mft
t3.43 in) | 12 24 inl
tr-r'10.8 mm(0.42 inl
or
VALVE GUIDE DRIVER, 5.5 mm
07742 - 0010100
Select the proper replacement guides. and chill them
in the freezer section of a refrigerator for about an
nour.
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 the head.
Do not got the head hottel than 300"F (150"C1;
excessive heat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
{cont'd)
6-41

Valve Seats
Reconditioning
1. Renew the valve seats in the cylinder
valve seat cutter.
NOTE: lf any guides are worn (see
replace them (see page 6-80) before
valve seats,
head with a
page 6-79),
cutting the
Carefully cut a 45o seat, removing only enough mate-
rial to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30" cutterand the lower edge of the seat with the 60. cutter.Check width of seat and adjust accordingly,
Make one more very light pass with the 45" cutter toremove any possible burrs caused bv the other cut-
ters.
Valve Seat Width:
Standard (Newl: 1.25 - 1.55 mm {0.0't9 - 0.061 in)Service Limii: 2.0 mm 10,08 inl
Sear Widrh
6-78
5. After resufacing the seat. inspect for even valveseating: Apply Prussian Blue Compound to thevalve face, and insert the valve in its original loca-tion in the head. then lift it and snap it closedagainst the seat several times.
PRUSSIAN BLUE COMPOUND
The actual valve seating surface, as shown by theblue compound, should be centered on the seat.. lf it is too high (closer to the valve stem), you mustmake a second cut with the 60. cutter to move itdown, then one more cut with the 45. cutter torestore seat width.
. lf it is too low (closer to the valve edge), you must
make a second cut with the 30. cutter to move itup. then one more cut with the 45. cutter to restoreseat width.
NOTE: The final cut should always be made withthe 45" cutter,
7. Insen the intake and exhaust valves in the head and
measure valve stem installed heioht.
Intaka Valve Stem Installed Height:
Standsrd lNaw): 37.465 - 37.935 mm(1./P50 - r.4935 inl
Sorvice Limit: 38.185 mm 0.5033 in)
Exhau3t Valv€ Stem Installed Height:
Standard (New): 37.165 - 37.6i|5 mm(1.46:t2 - 1.i1817 inl
Servico Limit 37.885 (1.4915 inl
lf valve stem installed height is over the service limit,replace the valve and recheck. lf it is still over the ser-vice limit, replace the cylinder head; the valve seat inthe h6ad is too deep.
(

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)

t
Five-step Troubleshooting
2.
1.Verify The Complaint
Turn on all the components in the problem circuit to
verify the customer complaint. Note the symptoms.
Do not begin disassembly or testing until you have
narrowed down the problem area.
Analyze The Schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by
tracing the current paths from the power feed
through the circuit components to ground. lf several
circuits fail at the same time, the fuse or ground is a
likely cause.
Based on the symptoms and your understanding of
the circult operation, identify one or more possible
causes of the problem.
lsolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis you made
in step 2. Keep in mind that a logical, simple proce-
dure is the key to efficient troubleshooting. Test for
the most likely cause of failure first. Try to make
tests at points that are easily accessible.
Fix The Problem
Once the specific problem is identified, make the
repair. Be sure to use proper tools and safe proce-
dures.
Make Sure The Circuit Works
Turn on all components in the repaired circuit in all
modes to make sure you've fixed the entire prob-
lem. lf the problem was a blown fuse, be sure to
test all of the circuits on the fuse, Make sure no new
problems turn up and the original problem does not
recur.
3.
Wire Color Codes
The following abbreviations are used to identify wire
colors in the circuit schematics:
wHT ............................. White
YEL ............................... Yellow
BLK ............,.,...............81ack
BLU .............................. Blue
GRN .............................Green
RED .......................,...... Red
ORN ............................. Orange
PNK .............................. Pink
BRN .............................. Brown
GRY .............................. Gray
PUR .,.................,.,........ Purple
LT BLU ......................... Light Blue
LT GRN ........................ Light Green
The wire insulation has one color or one color with
another color stripe. The second color is the stripe.
WHT/BLK
23-5

Power Mirrors
UNDER.OASHFUSE/FELAY BOX
Circuit Diagram {With Defogger)
BLK
G551
8LK
I
G551
YEURED
BLUMHT
8LK
II
-f,:
G551
23-208
UNDER-HOOD FUSE/RELAY BOX
/lr,---------- ---zlr
I'BLUELKl'YEUBEO
6
ORN/WHT

How To Use This Manual
Symbols
oo
Wire Color Abbreviations
The following abbreviations are used to
identify wire colors in the circuit schematics:
BLK.... .........b|ack
BLU.... ......... blue
BRN.... ,....... brown
GRN.... ........ green
GRY.... ......,.. gray
LTBLU . .....lightbtue
LTGRN. ....lightgreen
ORN.... ....... orange
PNK .... .......,.. pink
PUR .... ........ purple
RED .... .......... red
WHT... .........white
YEL .... ........ yellow
A broken line means this part of the circuit
is not shown; refer to the circuit listed for
the complete schematic.
"ral
o
-.1
See GroundDistribution,page 141.
I G101
Where separate wires
join, only the splice is
shown; for details on
the additional wiring,
refer to the circuits
listed.ili::i
{[
UNDER-OASHFUSE/RELAYBOX
Wires
A wavy line at the end of
a wire means lhe wire is
broken by the binding of
the book or by a "choice"
bracket but continues on
the next page.
Wire insulation can be
one color, or one color
with another color stripe.
(The second color is
the stripe.)
This circuit continues on
another page. (The arrow
shows direction o{ current
flow.) To tollow the RED/
BLK wire in this example,
you would turn to page 23-5
and look for the "2" anow.
This means the branch of the
wire connects to another
circuit. The arrow Doints to the
name of the circuit branch
where the wire continues.
8LK-Cruise Control, €aaaGauges, Indrcalors
!YEUsLK
Ttl
Wire choices for options or
different models are labeled
and shown with a "choice"
bracket like this.
This broken line means
both terminals are in
connector C134.
a.
+##l:i""lManuallransmission
ryil;::,
.""1
""'
"""1".'0
I
""^l
:-lName of Circuit

Connector Views (cont'd)
1. C202 (with Cruise Control)
- Gray- Left side ol engine compartment- Connects main wire harness to engine
compartment wre harness
gRN/BLK
(Cruise control)
BRN,ryVHT(Cruise control)
RED/BLK(Headlight switch)
BRN {Cruise conkol)
WHT/BLK(Front wipetwashel)5
4.c568
- Gray- Below Juel tank unit connector- Connects floor wire harness to tuel tank
pressure suo-narness
BLU (PGi.4-Fr)
LT GRN (PGM-FI)
BLl(WHT (PGI\4-FD
YEUBLU (PGM,FI)
GRN/BLK (PGI\,4.FD
4
5
2. C407 ('98-'00 Models)
- Gray- Behind left side ol dash, above kick panel
- Connects main wire harness to roof or moonroo{
wtre harness
WHT/RED(Ceiling light)
l\4ale - LT GRN/REDFemale - LT GRN/BLKor LT GRN/RED(Ceiling light)
5
5.c570
- Blue- In right door pillar- Connects floor wire harness to right rear door
wlre hafness
2
3
YEL(Power windows)
WHT/RED(Power door locks)
YEUGRN(Power wrndows)
YEL/BLK(Power windows)
YEURED(Power door locks)
5
6
3.c423
- Green- On Jront of under-dash tuse/relay box- On main wire harness
*1: YEL (Fuse 3)*2: GRN(Rear wiper/washe4
GRN/YEL(Turn signals)
GRN/ORN {Tu.n signals)
GRN/BLK(Front wiper/washer)
GRN/RED(Turn signals)
5
62
3
*1= USA: tX, EX, HX, DX-V SiCanada: EX, Si*2= Hatchback
202-2
6.c571
- Blue- In lett door pillar- Connects floor wire harness to lett rear door
wlre harness
MaIe _ YELFemale - GBN/YEL(Power windows)
WHT/RED(Power door locks)
Male - YEUGRNFemale - GBN(Power windows)
5
6
N4ale YEUBLKFemale - RED,ryVHT(Power windows)
YEURED(Power door locks)

\7. C604 (Hatchback)
GRN/BLK(Back-up lights)
l\4ale GRNIYELFemale - GRN/RED(Turn signaland hazardwarning lights)
BLK (G601)
- Gray- Left rear ol cargo area- Connects rear wire harness to left outer
taillight assembly
4
5
6
1
2
GRNAVHT(Brake lights)
FED/BLK(Headllght switch)
10. Exhaust Gas Recirculation
(EGR) Valve and Lift Sensor
1
2
3
(D16Y5 MfI D1685)
- Gray- Top right side of engine- On engine wire harness
WHT/BLK (EGR input)
GRN/BLK(Sensor ground)
YEUBLU(Reference voltage)
4
5
6
BLK (Ground)
PNK (EGR control)
of cargo area
rear wire harness to right outer
assembly
n- -n
a t | _ a2a
l3I4t5tttl
IJ
I
8. C605 (Hatchback)
- Gray- Right rear- Connects
taillight
GRN/BLK(Back-up lights)
GRNTYEL(Turn signaland hazardwarning lights)
3
4
5
6
1
2
BLK (G601)
GFNAVHT (Brake lights)
RED/BLK(Headlight switch)
11. Heater Fan Switch
('96-'98 Models)
- Brown
Center of dash- On heater-sub B wire harness
BLK (Ground)
BLUAVHT (L4edium
LO speed input)
BLU/BLK(Hl speed input)
4
5
6
1
2
3
BLU (LO speed input)
BLU/YEL (Medium
Hlspeed input)
GFIN (Blowerswitch ON input)
9. C607 (Hatchback)
- Blue- Right side o{ cargo area- On rear wire harness
BLU/BLK (lndicators)
RED/BLK(License lights)
GBN,ryVHT (8rake lights)
LT GBN(Rear wiper/washe0
5
6
1
2
3
4
GRN(Rear wiper/washer)
LT GRN/BLK(Rear \/iper washer)
)/
202-3
12. Security Starter Cut Relay/C416
- Natural* Upper left kick panel- On main wire harness
1
2Allexcept CX and DXI[,4ale: BLK,^r'r'HTFemale: BLKI/ELCX and DXi BLI(WHT(Battery input)
All except CX and DX:BLK^/ELCX and DX: BLK/WHT(Baftery input)
[.4ale - BLK/WHTFemale - BLKAVHTor BLKRED(Starter output)
All excepi CX and DX:RED/YELCX and DX: GRN(Security starter c!1relay control inpul)
5
6
tl3'

Connector Views (cont'd)
29. C120
- Gray- Top center of engine- Connects engine wire harness to distributor
assembly pigtail
All except '99-'00 016Y7/D16Y8:
l YEUGRN(lgnition input signal)
2 l\.4ale - LT BLUFemale - BLU(CKP sensor output)
3 Male - ORN/BLUFemale - GRN
[tDC sensor output)
4 l\.4ale - ORNFemale - YEL(CYP sensor output)
-= '96j98: All'99100: D1685
'99-'00 016Y7/D16Y8:
l YEUGRN(lgnition input signal)
2 Male - LT BLUFemale - BLU(CKP sensor output)
3 Male - ORN/BLUFemale - GRN
CIDC sensor output)
4 Male - ORNFemale - YEL
{CYP sensor output)
l\4ale - BLU/YELFemale - WHT(CKP sensor ground)
l\.4ale - WHT/BLUFCMAIE _ HtsL'(TDC sensor ground)
l\4ale - WHTFemale - BLK(CYP sensor ground)
Male - BLUFemale - . -*: BLU(Engine speed output)
BLK/YEL (lgnition input)
BLK/YEL (lgnition input)
WHT(CKP sensor ground)
Male - WHT/BLUFemale - RED
ffDC sensor ground)
BLK(CYP sensor ground)
10
202-8
30. c201
- Blue- Left side of engine compartment- Connects main wire harness to engine
compartment wire harness
l GRNA/EL(Turn signal and hazardwarning lights)
2 RED/BLK(Headlight switch)
3 REDAVHT(Headlight switch)
4 D16Y5:Male - GRN/BLKFemale -
Hatchbacki GRN/BLK
{Bear wipetwashe0
7
I
9b- 9/ mooets:lvlale - BLU/REDFemale BLK (Horns)'99-'00: Canada -
PNK (lndicators)
RED/BLU(Headlight switch)
BLU/RED (Fog lights)
GRN/RED
Cturn signal andhazard warning lights)
BED/GRN(Headlight switch)
RED/YEL(Headlight switch)
31. C359
- Orange- Right side ot engine compartment- Connects main wire harness to ABS modulator unit
10
l\4ale - REDAVHTFemale - GRNA/VHT(Power)
l\,4ale - BLKFemale - YEVBLK(FL-OUr)
Male - 8RNFemale BLIJ
{RR-OLrr)l\4ale BLUFemale - RED/BLK(FL-rN)
Male - PURFemale - RED&VHT(RR-rN)
6 Male - WHTFemale - YEUBLU(FR-OUr)
7 YEL (RL-OUr)
I Male - ORNFemale - RED/BLU(FR rN)
I Male GRNFemale - RED (RL-|N)
10 Male REDFemale - BLK,ryVHT(scol\,1)