cylinder HONDA CIVIC 1998 6.G User Guide

Cylinder Head/Valve Train
Dl6Y5, D16Y7, Dl6Y8 engines
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection ............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5 engine) ............................. 6-7
Manual Inspection
(D16Yg enginel ................'............ 6-7
Inspection Using Special Tools
{D16Y5 engine} .....................""'... 6-8
Inspection Using Special Tools
(D16Y8 engine) .........................'.'. 6-10
Valve Clearance
Adiustment ..."".....6-12
Valve Seals
Replacement (Cylinder head removal
not requiredl ................................ 6-1tl
Crankshaft Pulley and PulleY Bolt
Replacement ."...... &16
Timing Selt
lllustrated Index ............................... 6-17
Inspection .............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal ......,,......... 6-19
lnstallation ............. 6-20
Crankshaft Speed Fluctuation (CKF) Sensor
Repf acement .........6'22
Cylinder Head
lllustrated Index ............................... 6-23
Removal ................. 6-27
Warpage ................ 6-40
lnstallation ............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly ............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, D16Yg
enginesl "..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection .............. 6-36
Valves, Valve Springs and Valve Seals
Removal ........""..... 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement .........6-41
Reaming .......'......'.' 6-43
Valve Seats
Reconditioning .'....6'40
Valves
lnstallation ............. 6-tt3
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
lnstallation ............. 6-44

VTEC Solenoid Valve
Inspection
1.
6x1.0mm12 N.m 11.2 kgf.m,8.7 lbtft)
Disconnect the 1P connector from the VTEC sole-noid valve.
Measure resistance between the terminal and bodyground.
Resistance: l4 - 30 O
lf the resistance is within specifications, remove theVTEC solenoid valve assembly from the cylinder
head, and check the VTEC solenoid valve filter for
cloggrng.
. lf there is clogging, replace the engine oil filterand the engine oil.
VTEC SOLENOID VAI-VE ASSEMBLY
6-6
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4. lf the filter is not clogged, push the VTEC solenoidvalve with your finger and check its movement.
. lf the VTEC solenoid valve is normal. check the
engane oil pressure.
6x1.0mm12 N.m {1.2 kgt.m,8.7lbf.ft)
I
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..l'

VTEC Rocker Arms
2.
Manual Inspection (D16Y5 engine)
3.
1.
4.
Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Move the intake secondary rocker arm on the No. 'l
cylinder manually.
Check that the intake secondary rocker arm moves
independently of the primary intake rocker arm,
SECoNDARY PtROCKER ARM. Push and pull.
Check the intake secondary
cylinder at TDC.
rocker arm of each
a lf the intake secondary rocker arm does not move,
remove the primary and secondary intake rocker
arms as an assembly and check that the pistons in
the secondary and primary rocker arms move
smoothly.
a lf any rocker arm needs replacing, replace the pri-
mary and secondary rocker arms as an assembly.
PRIMARY ROCKER ARM
4.
Manual Inspection (D16YB engine)
1.Set the No. 1 piston at TDC.
Remove the cylinder head cover.
NOTE: Reter to page 6-46 when installing the cylin-
der head cover.
Push the intake mid rocker arm on the No. 1 cylin-
der manually.
Check that the intake mid rocker arm moves indepen-
dently of the primary and secondary intake rocker
arms.
MID ROCKERARM
Check the intake mid rocker arm of each cylinder at
TDC,
lf the intake mid rocker arm does not move.
remove the mid, primary and secondary intake
rocker arms as an assembly and check that the pis-
tons in the mid and primary rocker arms move
smoothly.
lf any rocker arm needs replacing, replace the
primary, mid, and secondary rocker arms as an
assemory.
5,
6-7

VTEC Rocker Arms
Inspection Using SpecialTools (Dl6Y5 enginel
CAUTION:
. Before using th6 Valve Inspection Tool, make 3ure
that ths air pressure gaugo on the air comptsssor
indicates over iloo kPa 14 kgf/cmr, 57 psi).
. Inspecl th6 valv€ clearance beforo rocker atm insDec"
tion,
'1.
Cover the timing belt with a shop towel to protect tho
belt.
Check ths intakg primaty rocker arm of each cylindqr atTDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Plug the relief hole with the special tool.
YY
OTLAJ - PR3O2OB
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3, Remove the sealing bolt from the inspection holeand connect the an air pressure regulator with a 0 -
100 psi gauge.
10 x 1.0 mmSEALING BOLT20 N.m {2.0 kgj'm. 14lblft}
l
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'10 x 1.0 mmADAPTER;NSp€CTTONHOLE (Commercially
available)
l'Pullthe dial andturn to adlust,
Loosen the regulator valve on the valve inspection
tool and apply the specified air pressure.
Spocified Air Pressurei
250 kPa {2.5 kg,t/cm,,36 psi}
o-at

VTEC Rocker Arms
Inspection Using Special Tools (D16Y8 enginel
CAUTION:
o Before using the Valve Inspection Tool. mak6 surethat the air pressure gauge on the air comprsssor
indicates ovor 400 kPa {4 kgf/cm,, 57 psil.
. Inspect th6 valve clearanco before rockar arm inspec-
tion.
. Cov€r th€ timing belt with a shop towel to protect
the bolt.
. Check tho intake prima.y rockff arm of each cylindel
at TDC.
1.Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylinder
neao cover,
Plug the relief hole with the specialtool.
OTLAJ - PR3O2OB
I,^ A IAo- tu
3. Remove the sealing bolt from the inspection hole
ancl connect an air pressure regulator with a 0 - 100psi gauge.
l0 x 1.0 mmSEALING EOLT20 N.m (2.0 kgf.m, 14 lbf.ft)
(AIR PRESSUREREGULATOR
{Commerciallyavailable). Pullthe dialandturn to adjust,

Valve Clearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylindsrhead temperature is less than 100"F (38"C).
. After adjusting, retorque the crankshaft pulley bolt(see page 6-16).
1, Remove the cylinder head cover.
NOTE; Refer to page e46 when installing the cytinderhead cover.
2. Remove the upper cover (see page 6-19).
3. Set the No. 1 piston at TDC. The "UP" mark on the
cam-shaft pulley should be at top, and the TDC
marks should align with the cylinder head surface.
TDC MARKS
4. Adjust valves on No, 1 cylinder.
Intako: 0.18 - 0.22 mm {0.007 - 0.009 in}
Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inl
"UP" MARK
6-12
No.4
5. Loosen the locknut, and turn the adjustment screwuntil the feeler gauge slides back and forth with asliOht amount of drag,
D16Y7 engin.:
CAUTION: Do not oyertighlen the locknuts; thorockor arms are made of aluminum.
INTAKE end EXHAUST VALVELOCKNUTS
Dl6Y5, Dl6Y8 engin€3:
INTAKE .nd EXHAUST VALVELOCKNUTS20 N.m 12.0 kstm, 14lbtft)
Adiusting screw locations:
IMTAKEo.4 1{o. 3 No. 2
tr'
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nb.3 No.2 No. 1EXHAUST
18 N.m (1.8 kgI.m, 13 tbl.ftl

6. Tighten the locknut, and check the clearance again.
Repeat the adjustment if necessary.
GAUGE
7.Rotate the crankshaft 180' counterclockwise (cam-
shaft oullev turns 90'1. The "UP" mark should be on
the exhaust side. Adjust valves on No. 3 cylinder.
"UP- MARK
t
8. Rotate the crankshaft '180' counterclockwise to
bring No.4 piston to TDC. Both TDC grooves are
once again visible. Adjust valves on No. 4 cylinder.
Rotate the crankshaft 180'counterclockwise to bring
No. 2 piston to TDC. The "UP" mark should be on
the intake side. Adjust valves on No. 2 cylinder.
-UP'MARK
6-13

Valve Seals
Replacement (Cylinder head removal not requiredl
NOTE: Cylinder head removal is not required in thisprocedure.
The procedure shown below applies when using the in-
car valve spring compressor (Snap-on YA884S withY48845 - 2 A7/8" attachment).
!@@ Alway wear approved eye protection whenusing ihe in-cai valve spring compressor.
1. Turn the crankshaft so that the No. I and the No. 4pistons are at top dead center (TDC).
2. Remove the cylinder head cover and the rocker arm
assembly.
NOTE:
. Refer to page 6-30 for rocker arm assembly
removat.
. When removing or installing the rocker armassembly, do not remove the camshaft holder
bolts. The bolts will keep the holders, springs
and rocker arms on the shaft.
. Refer to page 6-46 when installing the cylinder
head cover.
Remove the fuel injectors and the wire harness.
Using the 8 mm bolts supplied with the tool. mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit over the cam-
shaft as shown.
lnsert the cross shaft through the top hole of thetwo uprights.
3.
4.
6-14
Intake Valve Seals:
6. Select the 7/8 in diameter short compressor attach-ment, and fasten the attachment to the No. 4 hole of
the leve. arm with the speed pin supplied.
8.
7.lnsert an air adapto. into the spark plug hole. pump
air into the cylinder to keep the valve closed whilecompressing springs and removing the valve keepers.
Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
neao.
OIL PASSAGES
Position the lever arm under the cross shaft so thelever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for thespring being compressed. Use the front position
slot on the lever as shown.
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OIL PASSAGES
IN-CAR SPRING COMPRESSOR
SLOT

10. Using a downward motion on the lever arm, com-
.press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spring.
11. Remove the valve seals (see page 6-38).
12. Install the valve seals {see page 6-43).
13. Install the springs, the retainers and the keepers in
reverse order of removal.
Exhaust Valvs Sesls:
Select the 7/8 in. diameter short compressor attach-
ment, and fasten the attachment to the No. 2 hole of
the lever arm with the speed pin supplied.
Position the lever arm under the cross shaft so the
lever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for the
spring being compressed. Use the front position
slot on the lever as shown.
'14.
IN-CAR SPRING COMPRESSOR
7/8 in SHORT ATTACHMENT
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16.Using a downward motion on the lever arm, com-
press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spnng.
Remove the valve seals {see page 6-38),
Install the valve seals (see page 6-43).
Install the springs, the retainers and the keepers in
reverse order of removal.
Repeat steps 6 to 19 on the other cylinders.
't7.
'18.
19.
20.
6-15

Timing Belt
Illustrated lndex
NOTE:
. Refer to page 6-20 for how to position the crankshaft and pulley before installing the belt.
. Mark the direction of rotation on the belt before removing.
a Do not use the upper cover and lower cover for storing removed items,
. Clean the upper cover and lower cover before installing.
. Replace the ca mshaft seals and cra n kshaft sea ls if there is oil leakage.
. Refer to page 6-16 before installing the timing belt.
CYLINDER HEADCOVERReler to page 6-46when installing.
HEAD COVEB GASKETReplaco when l6akin9,domaged or deteriorated.Apply liquid gasket at
th€ lour corners of thetecessos.
d
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TIMING BELTInspection, page 6-18Adjustment, page 6-18Removal, page 6-19Installation. page 6-20
I x 1.25 mm3t N.m {3.8 kgf'm, 27 lbfftl
Apply engine oilto the bolt
thleads.
CRANKSHAFT SPEED FI.UCTUATION
lcr(Fl sENsoRReplacement, Page 6-22
UPPER COVEB
lnstallwithsurface facing in.
TIMING BELTDRIVE PULLEYReplacement, page 6_16
6x1.0mm9.8 N'm 11.0 kgt m,7.2 tbf.ft)NUBBER SEALSReplace when damagedor deledorated.
LOWER COVER
FUBBERPLUG
CRANKSHAFT PULLEYReplacement, page 6'16
PULLEY BOLTlil x 1.25 mm20 N.m 12.0 kgt.m,14 lbt'ft) + 90"Replacement, page 6'16Do not us6 an impactwrench when installing.
x 1.0 mmBOLT o-RING10 x 1,25 mm Reolace.14 N.m {,1.5 kgt m, 33 lbt ftl
6x1.0mmt2 N.m 11.2 kgf'm,8.7 tbt f0
9.E N'm (1.0 kgt.m,?.2 tbf.ftl\.-,o
6-17