Camshaft HONDA CIVIC 1998 6.G Workshop Manual

(urbY5, ul6Y7, Dl6Yg enl
MEASUREMENT
Sines) -Section6 -
STANDARD INFWTCompression250 rpm and wide open throftlekPa {kgf/cm,, psi) NominalMinimumMaximum variationWarpageHeight
End play
Camshaft to-holder oil clearanceTotal runoutCam lobe height D16y7
D16Y5
D16Y8
INEXIN
EXIN
EX
Secondary
PrimaryMidSecondary
930 {9.5, 135)200 12 0 ?R\Cylinder head
92.95 - 93.05 {3.659 3.663)0.05 {0.002)
Camshaft0.05,0.15 (0.002 0.006)0.050 - 0.089 (0.002 _ o.oo4)0.03 (0.001)max.
35.299 (1.3897131.241 /.1.4678)38.427 (1.5129)32.193 11 .267 4l38.784 (1.5269)
36.778 (1.4479)
38.274 (1.5068)
37.065 .4592)38.008 (1.4964)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
=
Valve clearanca {Cold)
Valve stem O.D.
Stem-to guide clearance
width
Stem insta ed height
Free lengrh Dt6y7D16Y5
INEXINEXINEX
INEXINEX
INEXINEX
INEXINEX
D16Y8
t.D.
Installed height
0.18 - 0.22 10.007 - 0.009)0.23 0.27 (0.009 0.011)5.48 - 5.49 (0.2157 0.2161)5.45 - 5.46 {0.2146 _ 0.2150}0.02 - 0.05 (0.001 _ o.oo2)0.05-008lono2-nnn?l
5.45 (0.2146)
5.42 tO.213410.08 (0.003)
0.11 (0.004)
1.6 (0.063)
2.0 (0.079)
53.a9 \2.122|j$.a9 Q.122)
Valve seat0.85 - 1.15 (0.033 - 0.045)1.25 - 1.55 10.049 - 0.061i53.17 - 53.64 {2.093 _ 2.112)53.17 - 53.64 (2.093 _ 2.112)Valve spring57 .9 (2.2a)
56.5 \2.22157 .9 t2.29l58.0 (2.2a)
58.7 {2.31iValve guide5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 _ 0.218)17.85 - 18.35 \0.103 - 0.722)18.65 19. t5 (0.734 _ 0.754)
5.55 t0.219)5.5s {0.219)
Rocker armArm-to shaft clearanceINEX0.017 - 0.050 (0.0007 0.0020)0.018 - 0.054 (0.0007 - 0.0021)0.08 (0.003)
0.08 (0.003)
Standards and Service Limits
Cylinder Head/Valve Train (Dt6y5, Dt6y7, D
L,
ra
3-2
LO

Unit of iength: mm (!n)
930 (9.5, 135)20012.0,zal
0.05 - 0.15 (0.002 - 0.006)
0.050 - 0.089 (0.002 - 0.004)
0.0310.001)max.33.088 (1.3027i
36.261 {1.4278)34.978 (1.3771)
32.785 {1.2907)35.720 (1.4063)
34.691 (1.3658)
u*u lo.r,ool5.420 (0.2134)
0.08 (0.003)
0.11 (0.004)
2.0 (0.08)
2.0 (0.08)
38.185 (1.5033)
37.885 (1.4915)
250 rpm (min riand Nominal
wide open throttle Minimum
kPa (kqf/cm', psi) Maximum variation
End play
Camshaft-to holder oil clea€nce
Total runoutCam lobe height lN PrimaryMidSecondaryEX PrimaryMidSecondary
0.15 - 0.19 (0.006 - 0.007)*
0.17 - 0.21 (0.007 - 0.008)*
5.475 - 5.485 10.2156 - 0.2159)
5.450 - 5.460 (0.2146 - 0.2150)
0.025 - 0.055 (0.0010 0.0022)
0.050-0.080 (0.0020 - 0.0031)
Valve clearance
Valve stem O.D.
Stem-to-guide clearance
INEXINEXINEX
1.25 - 1.55 {0.049 - 0.061)r.25 - 1.55 (0.049 - 0.061)
37.465 - 37.935 (1.4750 - 1.4935)
37.165 - 37.635 (1.4632 - 1.4817)
INEXINEX
width
Stem installed height
40.92 (1.611)*'
40.91 (1.6111"
36.71 (1.415)
41.96 (1.652)*r
4 r.94 (1.651)*'
free t*gth lN OUTER
5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 - 0.218i12.55 - 13.05 (0.494 0.5'j4)
12.55 - 13.05 (0.494 - 0.514)
LD. lNEX
Installed height lNEX
0.025 - 0.052 (0.0010 0.0020)
o.o2s - 0.052 {0.0010 0.0020)
Cylinder Head/Valve Train(816A2 engine) - Section
MEASUREMENTSTANDARD INEW)SERVICE LIMIT
*: Measuring point between camshaft and rocker arm'*1: NTHON H;TSUJO manufactured vatve spring. *2: CHUO HATSUJO manutactured valve spnng.
3-3

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

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.
,
I
i'
OIL PASSAGES
IN-CAR SPRING COMPRESSOR
SLOT

Timing Belt
Inspection
1.
2.
3.
Remove the cylinder head cover.
. Refer to page 6 46 when installing.
Remove the upper cover (see page 6 19).
Inspect the timing belt for cracks and oil or coolantsoakrng.
NOTE:
. Replace the belt if oil or coolant soaKeo.. Remove any oil or solvent that gets on the belt.
Rotate pulleyand inspect belt.
After inspecting, retorque the crankshaft pullev bolt{see page 6- 16).
o- I6
Tension Adjustment
CAUTION: lt*ays aa;j"t the timing bett rension withthe engine cold.
NOTE:
. The tensioner is spring loaded to apply tension to thebelt automatically after making the following adjustment.
. Always rotate the crankshaft counterclockwise whenviewed from the pulley side. Rotating it clockwisemay result in improper adjustment of the belt ten-sion.
. lnspect the timing belt before adjusting the belt ten-ston.
1.Remove the cylinder head cover.
. Refer to page 6,46 when installing.
Remove the upper cover (see page 6,'19).
Rotate the crankshaft five or six revolutions to setthe belt.
Set the No. 'l piston at TDC (see page 6-21).
Loosen the adjusting bolt 180'.
2.
3.
4.
5.
\I
ADJUSTING BOLT44 N.m {4.5 kgt m,33 rbf.ft)
7.
8.
Rotate the crankshaft counterclockwise three teethon the camshaft pulley.
Tighten the adjusting bolt.
After inspecting, retorque the crankshaft pulley bolt(see page 6-16).

Timing Belt
Removal (cont'd)
9. Remove the CKF sensor from the oI pump.
10. Loosen the adjusting bott lgO..to remove tension from theretighten the adjusting bolt.
12 N.m 11.2 kgt.m,8.7 rbf.ftl
Push the tensioner
timing be lt. then
AD.'USNNG BOLT4{ N.m 14.5 kgt m,33 tbtftl
1 1. Remove the timing belt.
6-20
lnstallation
Install the timing belt in the reverse order of removal;Only key points are described here.
l. set rhe timing belt drive pulley so that the No. 1 pis-ton as at top dead center (TDC), Align the groove onthe timing belt drive pulley to the pointer on the oilpump.
TDC MARKPOINTER
I
t
I
TIMING BELTDBIVE PULLEYClean.I
2. Set the camshaft pulley to TDC. Align the TDCmarks on the camshaft pulley to the cylinder headsurface.

3. Install the timing belt tightly in the sequence shown'
OTiming belt drive pullev (crankshaft) )@Adjusting
pulley -towater pump pulley J@Camshatt pulley'
NOTE: Make sure the timing belt drive pulley and
camshaft PulleY are at TDC
7.
Loosen and retighten the adiusting bolt to tension
the timing belt.
lnstall the lower cover and upper cover.
NOTE: Clean the upper and lower covers before
installation.
lnstall the crankshaft pulley, then tighten the pulley
bolt (see page &16)
Rotate the crankshaft pulley about five or six turns
counterclockwise so that the timing belt positions
on the Pulleys.
Adjust the timing belt tension (see page 6-18).8.
L
9. Check that the crankshaft pulley and camshaft pul-
ley are both at TDC.
CRANKSHAFT PULLEY:
CAMSHAFT PULLEY:
lf the camshaft and crankshaft pulleys are not posi-
tioned at TDC, remove the timing belt and adjust
the position following the procedure on page 6-20'
Then reinstall the timing belt.
After installation, adjust the tension of each belt
. See section 23 for alternator belt tension adjust-
ment.
a See section 22 tot NC compressor belt tension
adjustment.
. See section 17 for P/S pump belt tension adjust
ment,
(wHrTE)
"UP" MARK
TDC MARK
11.
6-21

Cylinder Head
lllustrated Index (cont'dl
(-/) _.- E "or to reassembring, crean at the parts in sorvent, dry them and appry rubricant to anv contact oarts.
D16Y7 engine:
ROCK€R ARMASSEMBLYRemoval, page 6 30Inspection, page 6-35
8 x 1.25 mm20 N.m (2.0 kgt.m, 14 tbt.ftlApply engine oil to the
H
B
O-RINGReplace.
INTAKE VALVE SEALReplace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
:a
ti
VALVE
SPRING RETAINER
EXHAUST VALVESEAL
VALVE SPRINGSEAT
EXHAUST VALVEGUIDErnspectron, page 6,39Beplacement, page 6 4lAeaming, page 6-43
8 x 1.25 mm37 N m (3.8 kgt m,27 tbtftlApply engine oiltothe threads.
INTAKE VALVERemoval, page 6-38lnstallation, page 6-43
Removal, page 6,27Warpage, page 6 40Valve seat reconditioning,page 6-40Installation, page 6-45
VALVE
t
t
t
CAMSHAFTnspectron, page 6-36
OIL CONTROLORIFICEClean.
KEEPERS
\
EXHAUST VALSPRING
c -A9-2.+
L
6x1.0mm12 N.m (1.2 kst.m, 8.7 tbf.ft)Apply engine oit to thethreads.
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVESPRING

D16Y5 engine:
I x 1.25 mm20 N.m (2,0 kgf m, 14 lbf ft)
Apply engine oilto the
threads.ROCKEB ARMASSEMBLYFemoval, page 6-30
Inspection, Page 6-34
6x1.0mm12 N.m 11.2 kgf m, 8.7 lbf'ftl
Apply engine oilto the
threads.
VALVE KCEPERS
SPRING RETAINER
CAMSHAFTInspection, page 6-36
6x1.0mm12 N,m 11.28.7 tbf.ft)
WEC SOLENOIDVALVEBINTAKE VALVESPRING
INTAKE VALVE SEAL
Replace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
CAMSHAFTPUL|'IY
VTEC SOLENOIDVALVE FILTERReplace.
OIL CONTROLORIFICEClean.
VALVE
SPRING RETAINEB
EXHAUST V
SPRING
VE
EXHAUST VALVE
SEALt"o'""".uoau,
SEATReplace.
GUIDEInspection, page 6-39Replacement, Page 6-41
Reaming, page 6-43EXHAUSTVALVEOIL SEALReplace.
HEAD
8 x 1.25 mm
37 N.m 13.8 kgf.m,
27 tbf.frlApply engine oiltothe lhreads.
(cont'd)
6-25
INTAKE VALVERemoval, page 6 38
Installalion, Page 6 43Removal, page 6-27Warpage, Page 6 40
Valve seat reconditioning'page 6-40lnstallation, page 6_45

Cylinder Head
lllustrated Index (cont'dl
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVE
VTEC SOLENOIDVALVE FILTEBReplace.
OIL CONTROLORIFICEClean.
INTAKE VALVE SEALReplace.VALVE SPRINGSEAT
INTAKE VAI.VEGUIOE
CAMSHAFTPULLEY
I
I
VALVE KEEPERS
SPRING RET
EXHAUST VALVESPRING
@
EXHAUST VALVESEALReplace.
8 x 1.25 mm37 N.m 13.8 kgt m,27 tbfitlApply engine oiltothe threads.
EXHAUSTVALVE
-vp
e,.io"o reassembring, crean at the parts in sorvent, dry them and appry rubricant to any contact parts.
D16Y8 engine:
LOST MOTIONASSEMgLY
ROCKER ARMASSEMBLYRemoval, page 6 30Inspection, page 6-34
5xl.0mm12 N.m {1.28.7 tbf.ft)
VALVE SPRINGSEATEXHAUSTVALVE O.RINGGUIDE Replace.Inspection, page 6 39Replacement, page 6 41Reaming, page 6 43
LOST MOTIONASSEMBLYHOLDER
INTAKE VALVEBemoval, page 6 38Installation, page 6 43
20 N.m 12.0 kgl.m, 14 tbf.ft)Apply engine oit to thethreads.
\
\
s9illl
CAMSHAFTInspection, page 6-36
OIL SEALBeplace.
CYLINDER HEADRemoval, page 6 27Warpage, page 6-40Valve seat reconditioning,page 6 40Installation, page 6-45
6x1.0mm12 N.m (1.2 kgt.m,8.7 lbf.ftlApply engine oil to thethreads,