engine parts HONDA CIVIC 1998 6.G User Guide

Cylinder Head
Installation (cont'dl
10. Align the marks on the cylinder head plug to thecylinder head upper surface, then install the cylin,
der head plug in the cylinder head.
PLUGReplace.
Install the timing belt (see page 6-63).
Adjust the valve clearance (see page 6-61).
Install the head cover gasket in the groove of the
cylinder head cover. Seat the recesses for the
camshaft first, then work it into the groove around
the outside edges,
NOTE:
. Before installing the head cover gasket, thorough-ly clean the head cover gasket and the groove.
. When installing, make sure the head cover gasket
is seated securely in the corners of the recesses
wrrn no gap.
11.
13.
1'
CYLINDEB HEAD
HEAD COVEB
6-86
(\
14. Apply liquid gasket to the head cover gasket at theeight corners of the recesses.
NOTE:
. Use liquid gasket, Part No. 08718 - 0001 or 08718- 0003.
. Check that the mating surfaces are clean and drybefore applying liquid gasket
. Do not install the parts if five minutes or morehave elapsed since applying tiquid gasket.
Instead, reapply liquid gasket after removing oldrestdue.
. After assembly. wait at least 30 minutes before
filling the engine with oil.

15. When installing the cylinder head cover, hold the
head cover gasket in the groove by placing your fin-
gers on the camshaft holder contacting surfaces
(toD of the semicircles).
Once the cylinder head cover is on the cylinder
head, slide the cover slightly back and forth to seat
the head cover gasket.
NOTE:
. Be{ore installing the cylinder head cover, clean
the cvlinder head contacting surfaces using a
shoP towel.
. Oo not touch the parts where liquid gasket was
applied.
. Replace any washer taht is damaged or deter'o-
rated.
t
\
6-A7
16. Tighten the nuts in two or three steps. In the final
step, tighten all nuts, in sequence, to 9 8 N'm {1 0
kgf.m, 7.2 lbf.ft).
NOTE: After assembly, wait at least 30 minutes
before filling the engine with oil.
After installing, check that all tubes' hoses and con-
nectors are installed correctly.17.

lllustrated Index
I runricate att internal parts with engine oil during reassembly'
NOTE:
o Apply liquid gaskettothe mating surfaces ofthe right side cover and oil pumpcase before installingthem'
. Use liquid gasket, part No 08718-0001 or08718-0003'
. Clean the oil pan gasket mating surfaces betore installing the oil pan
81642 engine:
DRAIN BOLT44 N,m {4.5 kgf'm,33 lbt'ft)
6 x 1.0 mm'11 N.m (1.1 kgI'm,
I tbl.ft)
OIL PANReter to page 7 27when installing.
6 r 1.O mm12 N.m t1.2 kgl'm, 8 7 lbf'lt)
OIL PAN GASKET
BUFFLE PLA
12 x 1.0 mm103 N.m {10.5 kgf'm,
76 tbr.ft)
6 x 1.0 mm11 N.m (1 .1 kgf.m,
8 tbI.fr)
GASKETReplace.FLYWHEEL(M/TI
12 x 1.0 mm
74 N.m (7.5
kof.m, 54 lbf'ft)
1^c{Eb\%^ t*^
*o"rr^--(Wffi
oa*,trto2,.w
FLYWHEEL COVER
IM/T)
DRIVE PLATECOVER (AiT)
11 x 1.5 mm76 N.m (7.9 kgf'm, 56 lbf'ft)
Apply engine oil to the bolt
threads.NOTE: After torqurngeach cap, turn crankshaft
to check for binding.
MAIN EEARING CAP
MAIN BEARINGSSelection, page 7_10
NOTE: New main bearings musl
be selected bY matching crank
and block identification markrngs
CRANKSHAFTInstallation, Page 7'23
OIL JET BOLT16 N.m 11.6 kgf'm, 12 lbl'ft)
OIL JETInspection, Page 8_10
Check for cracks
6x1.0mm11 N.m {1.1 kgf'm, I lbf'ft}
CRANKSHAFT OIL SEAL
Installation,pagesl 22 andl 29
Replace-
DOWEL PINOIL PUMPOverhaul, page 8-'l1Removal/lnspection,page 8-13.Apply liquid gasket
to mating surlace.RIGHT SIDE COVERApply liquid gasket
to mating surface.
THRUST WASHERS8 x 1.25 mm24 N.m {2.4 kgf.m, 17 lbf'ft)Grooved sides face outward
NOTE: Thrusr washer thickness
is tixed and must not be changed
by grinding or shimming
O-RINGReplace
CRANKSHAFT SEAL11 N.m {1.1 kgf'm, lnstallation, pages 7'29 and I 14
a lbt.ltl Heplace. (cont'd)
d#*

lllustrated Index
(cont'dl
I Luoricate att internal parts with engine oil during reassembly.
NOTE:
' Apply liquid gasket to the mating surfaces ofthe rightside coverand oil pumpcase before installingthem.. Use liquid gasket, part No. 08718 - 0001 or 087,18 _ OOO3.. Clean the oil pan gasket mating surfaces before installing it.
D16Y7 engine:6 x 1.0 mm12 N.m (1.2 kgt.m.8.7 tbf.tr)DRAIN BOLT44 N.m {4.5 kgt.m.33 tbt.ttl
,(
I
I
OIL PAN GASKETFLYWHEEL COVERIM/T)6x 1.0 mm12 N.m ('l .2 kgt.m, 8.7 tbt.trl
OIL PANRefer to page 7-27
Apply liquid gasker tothese points.
Replace.
WASHERReplace.12 x '1.0 mm118 N.m{12.0 kgt.m, 87 tbf.tr}
11 x 1.5 mm51 N.m15.2 kgl.m,38lbtftl
Apply engine oilto the boltthreads.NOTE: After torquingeach cap, turn the crankshaftto check for binding.
MAIN BEARINGSSelection, page 7-10
MAIN BEARING CAP
CRANKSHAFTInstallation, page 7 23
NOTE: New main bearings mustbe selected by matching crankand block identification markings.
6 r 1.0 mm11 N.m {1.1
6 x 1.0 mm11 N.m 11.1
ksI.m, 8 lbt.ft)
OIL SCREEN
kgt.m, 8 lbf.trl
Check for cracks.
CRANKSHAFT OIL SEALInstallation,pages 1 22 a^d 7-29
\:eprace'
GASKETReplace.
6 x 1.O mm11 N.m {1.1 kgt.m,8 rbt.frl
RIGHT SIDE COVERApply liquid gasker1o matrng surface,
OIL PUMPOverhaul, page 8-12Bemoval/lnspection,page 8-13
DOWEL PIN
WASHERSGrooved sides face outward.NOTE: Thrust washer thicknessis fixed and must not be changedby grinding or shimming.
CRANKSHAFT SEAL
l.j"Ji:l"^ pages z.2e --.S)
Replace.
6 x 1.0 mm11 N.m {1.18 tbt.fr)
7-4
BREATHING PORT COVERMOUNT BOLTS6 x 1.0 mm11 N.m {1.1 kgt.m, 8 tbf.fr}Apply liquid gasker tothe boh threads.
DOWEL PIN

lllustrated Index
(cont'd)
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft(see page 7,11).identification markings
Lubricate all internal parts with engine oil duringreassembtv.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTON RINGSReplacement. page 7-20Measurement, pages 7 20 andj-21Alignment, page 7-21
PISTON PINRemoval, page 7,17Installation, page 7-18Inspection, page 7,19
CONNECTING RODEnd play, page 7-8Selection, page 7,18
CONNECTING RODBEARINGSClearance, page 7 11Selection, page 7-11
CONNECTING ROD BEARING CAPInstallation, page 7-23NOTE: lnstall caps so thebearing recess is on thesame side as the recessin the rod.
PISTONInspectron, page 7-15NOTE: Betore removing the piston, inspect thetop of the cylinder bore for carbon build-up orridge. Bemove ridge if necessary, page 7-13
ENGINE BLOCKCylinder bore inspection, page 7-16Warpage inspection, page 7,'16Cylinder bore honing, page 7,17
Inspect top of each cylinder borefor carbon build-up or ridgebefore removing piston.Remove ridge if necessary, page 7-13
CONNECTING ROD CAP NUT816A2 €ngin6:9 x 0.75 mm{0 N.m (4.1 kgt m, 30 tbf.ftlD16Y5, Dl6Y7. D16Y8 engines:8 x 0.75 mm3l N.m {3.2 kg{.m,23 tbt.fr)Apply engine oiltothe bolt threads.NOTE: After torquing each bearingcap, rotate crankshaft tocheck for binding.
7-6

Crankshaft
Installation (cont'd)
7. Installthe main bearing caps.
Check clearance with plastigage (see page 7-9), thentighten the bearing cap bolts in 2 steps.
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft)
Second stop:
B1642 engine:
76 N.m {7.8 kgf.m, 56 lbf.ft)
D16Y5, D16Y7, D16Y8 engines:
51 N.m (5.2 kgf.m, 38 lbf.ft)
NOTE: Coat the thrust washer surfaces and boltthreads with oil.
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
oocoo
CAUTION: Whenever any crankshaft or connectingrod bearing is replaced, it is necGssary after reassom-bly to run the engine at idling spe6d until it reachesnormal operating temperature, than continue to runit for approximately 15 minutos.
:V fr\-/.---\-/.-
7-24
NOTE:
. Use liquid gasket, part No. 08718 - 0001 or08718-0003.
. Check that the mating surfaces are clean and drybefore apptying liquid gasket.
. Apply liquid gasket evenly, being careful to coverall the mating surface.. To prevent oil leakage, apply liquid gasket to theinner threads of the bolt holes.. Do not install the parts if five minutes or morehave elapsed since applying the liquid gasket.
Instead reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
L Apply liquid gasket to the block mating surface ofthe right side cover, then install it on the cylinderblock.
Bl6A2 engine;
Apply tiquid gaslet alongthe broken line.
D16Y5, D16Y7, D16Y8 engines:
RIGHT SIDE COVER

2. Apply liquid gasket to the block mating surfaces of
the oil pan, then install it. Apply liquid gasket to the
shaded areas.
NOTEI
. Use liquid gasket part No. 087 18 - 0001 or
08718 - 0003.
. Check that the mating surfaces are clean and dry
before apPlying liquid gasket.
. Apply liquid gasket as an even bead, centered
between the edges ol the mating surface'
. To prevent leakage of oil, apply liquid gasket to
the inner threads of the bolt holes
. Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket
lnstead, reapply liquid gasket after removing the
old residue
. After assembly, wait at least 30 minutes before
filling the engine with oil.
Tighten nuts finger-tight
below.
OIL PAN
at six points as shown
I
3.
4. Tighten all bolts and nuts, starting from nut @, clock-
wise in three steps.
NOTE: Excessive tightening can cause distortion of
the oil pan gasket and oil leakage.
Torque: 12 N'm {1.2 kgt'm,8.7 lbf'ft|
816A2, D16Y7 engines:
1. Apply liquid gasket on the oil pump and right side
cover mating areas as shown below.
NOTE:
. Use liquid gasket, part No. 08718 - 0001 or
08718 - 0003.
. Check that the mating surfaces are clean and dry
before applying liquid gasket
. Apply liquid gasket as an even bead, centered
between the edges ol the mating surface'
. To prevent oil leakage, apply liquid gasket to the
inner threads of the bolt holes
. Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket
Instead, reapply liquid gasket after removing the
old residue.
. Aftel assembly, wait at least 30 minutes before
filling the engine with oil.
CYLINDERELOCKApply liquid gasket
to these pornts-
Apply liquid gasket
to these pornts.
(cont'd)
7 -27

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.

Radiator
Replacement
Drain the engine coolant.
Remove the upper and lower radiator hoses, andATF cooler hoses.
Disconnect the fan motor connector.
Remove the radiator upper bracket, then pull up theraotator,
RADIA
ATF COOLERHOSES (A/T)Refer to sectionwhen installing.
UPPER RAOIATOR HOSE
6x1.0mm7.2 N.m (0.73 kgf.m.5.3 tbf.ft)
1.
2.
3.
5. Remove the fan shroud assemblies and other partsfrom the radiator.
Install the radiator in the reverse order of removal:
NOTE:
. Set the upper and lower cushions securely.. Fill the radiator with engine coolant and bleedthe air.
6x1.0mmCAPY|lT,PS:|" i.i ru- ii b rgr.-,AND CUSHION7.2 tbr.ftl
14
(
I
RESEBVOIR TANK
RADIATOR
LOWER CUSHION
RAOIATOR FAN/SHROUDASSEMBLY
DRAIN PLUGO-RINGReplace.
LOWER RAOIATOR HOSE
ATF COOLERPIPES {A/T)
,iiiiii
10-6

tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK