primary o2 HONDA CIVIC 1999 6.G User Guide

Remove the cylinder head cover.
NOTE: Refer to page 6-88 when installing the cylin-
der head cover.
Push the mid rocker arm on the No. 1 cylinder man-
ually.
Check that the mid rocker arm moves independently
of the primary and secondary rocker arms.
Check the mid rocker arm ot each cylinder at TDC'
. lf the mid rocker arm does not move, removs the
mid, primary and secondary rocker arms as an
assembly and check that the pistons 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
assembly.
7.
2. Plug the
per).
Inspection Using SPecial Tools
CAUTION:
. B€fore using tho Yalvo inspeciion tool, mako suro
that ths air pre3sure gauge on the air comprossor
indicatos ovor /rco kPa (,1 kgf/cm', 57 psi)
. In3poct ths valve closranca bafore rock$ arm impoc'
tion.
. Cover the timing beh whh I shop towel to prcvenl
gstting oil on the bolt'
. Chock ths mid rocker arm of each cylindll at TDC'
1. Remove the cYlinder head cover.
NOTE: Rsfer to page 6-86 when installing the cylin-
der head cover.
relief hole with the special tool (Air Stop-
OTLA' - PRSO2OA
3. Remove the bolt and washer from the inspection
hole and connoct the an air pressure regulator with
a 0 - 100 psi gauge.
AIF STOPPEBTNSPECTION HOIEOTLA' - PR3O2OA
t0 x 1.0 mrn20 N.m {2.0 kgf m,14 tbt'fr)
AIR PRESSUREREGULATOR{Cornm.rcirlly avril.bl.lBEGULATOR VALVE. Pull the lever andturn to adjust.{cont'd}
6-55

VTEC Rocker Arms
4.
Inspection Using Special Tools (cont,dl
Loosen the valve on the regulator and apply thespecified air pressure.
Specified Air Pressuro:
250 kPa {2.5 kgtlcm,, 36 psil- 490 kPa {5.0 kgtcm,, 7t psil
Make sure that the primary and secondary rockerarms are mechanically connected by the pistonsand that the mid rocker arms do no. move wnenpushed manually.
SECONDARYROCKER ARM
. lf any mid rocker arm moves independently ofthe primary and secondary rocker arms, replacethe rocker arms as a set.
Remove the tools.
Check the operation of the lost motion assembly bypushing on the mid rocker arm. The lost motionassembly should compress fully and operatesmoothly through its full stroke. Replace the assem_bly if it does not work smoothly.
After inspection. check that the Malfunction Indi_cator Lamp {MlL) does not come on.
7.
6-56
I
ll
;l

WATER BYPASS
HOSE
14. Remove the upper radiator hose, heater hose and
water bvpass hose.
HEATER
Remove the engine wire harness connectors and wlre
harness clamps from the cylinder head and the intake
manifold.
Four fuel injector connector
Engine coolant temperature (ECT) sensor connec-
tor
ECT gauge sending unit connector
ECT switch connector
ldle air control (lAC) valve connector
Manifold absolute pressure (MAP) sensor connec-
tor
Throttle position sensor connector
Primary Heated oxygen sensor (Primary HO2S)
connecror
VTEC solenoid valve connector
15.
a
a
a
a
a
\
16.
17.
Remove the spark plug caps and distributor form
the cylinder head.
Remove the upper bracket.
NOTE:
. Use a jack to support the engine before removing
the upp€r bracket is removed.
. Place a cushion between the oil panandthejack.
12 x 1.25 fin74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cylinder head cover.
{cont'd)
6-69

Rocker Arms and Lost Motion Assemblies
Inspection
NOTE: When reassembling the primary rocker arm, care-
fully apply air pressure to the oil passage of the rocker
arm.
PRIMARY ROCKER ARM
MID ROCKER ARM
Inspect each rocker arm piston. Push it manually
- lf it does not move smoothly. replace the rocker
arm assemDly.
1.
SECONDARY
Check prston movement
NOTE:
. Apply oilto the pistons when reassembling.
. Bundle the rocker arms with a rubber band to
keep them together as a set.
PISTONS
PRIMARY
\
6-73
2. Remove the lost motion assembly from the cylinder
head and inspect it. Test it by pushing the plunger
with your finger,
- lf the lost motion assembly does not move
smoothly, replace it.
LOST MOTION ASSEMBLY
Push
I

Rocker Arms and Shafts
Clearance Inspection
Measure both the intake rocker shaft and exhaust rocker
shaft.
1. Measure diameter of shaft at the first rocker loca-
tron.
2. Zero gauge to shaft diameter.
Surlace shor/ld be smooth.
MICROMETER
6-74
3. Measure the inside diameter of each rocker arm and
check for out-of-round condition
Rocker Arm-to-Shaft Clearance:
Intake and Exhaust
Standard {Newl: 0.025 - 0.052 mm
{0.0010 - 0.0020 in)
Service Limit: 0.08 mm {0.003 in)
Inspect rocker armface for wear.
Repeat for all rockers.- lf over limit, replace rocker shaft and all overtol-
erance rocker arms.
NOTE: lf any rocker arm needs replacement, replace
all three rocker arms in that set {primary, mid, and
seconoary).

Gamshafts
Inspection (cont'dl
7. lf the camshaft-to-holder oil clearance is out of tol-
erance:
- And the camshaft has already been replaced, you
must replace the cylinder head.- lf the camshaft has not been replaced, first check
the total runout with the camshaft supported on
V-blocks.
Camshaft Total Runout:
Standard (New): 0.03 mm {0.001 in} max.
Service Limit: 0.04 mm (0.002 inl
- lf the total runout of the camshaft is within toler,
ance, replace the cylinder head.- lf the total runout is out of tolerance. replace the
camshaft and recheck the camshaft to,holder oil
clearance. lf the oil clearance is still out of toler-
ance, replace the cylinder head.
INTAKEEXHAUST
PRIMARY33.088 mm
{1.3027 in)
32.785 mm
(1.2907 inl
MID36.267 mm(1.4278 in)
35.720 mm
{1.4063 in)
SECONDARY34.978 mm(1.3771 inl
3i1.691 mm(1.3658 in)
8. Check the cam lobe height.
Cam lobe height standard (New):
Cam Position
I
INTAKE
MID
EXHAUST
SEC MID PRI
TIB
T/B: TIMING BELTPRI: PRIMARYMID: MID
Check thrs area lor wear.

Exhaust Manifold
Replacement
NOTE: Use new gaskets and self-locking nuts when reassembling.
CAUTION:
. Check for folds or scratch€s on the surface of the gasket.
. Replace with a new gasket it damaged.
D16Y5. D16Y7 engines:
I x 1.25 mm24 N.m {2.4 kgt.m, 17 tbtft}
MANIFOLDBRACKET
PRIMARY HEATEDOXYGEN SENSORIPRIMAFY HO2SI44 N.m {4.5 kgf m, 33 lbtft)Replacement, page 9-12
GASKETReplace.
I x 1.25 mm31 N.m (3.2 kgf.m,23 tbf.ft)Beplace.
WAY CATALYTICCONVERTER {TWCIlnspection, page 9'12
6x1.0mm11 N.m {1.1 kgt m,8 lbf.ft)
SECONDARY HEATEDOXYGEN SENSOR(SECONDARY HO2S}44 N.m 14.5 kgf.m,33 lbf.ft)Replacement, page 9-13
9-6

D15Y8 engine:
8 x 1.25 mm2,1 N.m (2.a kgf'm,
17 tbf.ftl
GASKETReplace.
8 x 1.25 mm31 N.m 13.2 kgf'm,23 lbf.ftlReplace.
PRIMARY HO2S44 N.m (4.5 kgf.m, 33 lbtft)Replacement, page 9-13
EXHAUST MANIFOLDBRACKET10 x 1.25 rnm
(cont'd)
9-7
/r4 N.m {4.5 kgf.m, 33 lbf.ft)
v

816A2 engino:
MUFFLER_.,. EXHAUST PIPE
-/- tlP
g
\6r1.omm
9.8 N m 11.0 kgf'm, 7.2 lbl'ttl
GASKETReplace.
8 x 1.25 mm2. N'm 12.2 kgl-m,t6 tbtf0Replace.Tighten the bolts insteps, alternatrngside-to-side.6x1,0mm9,8 N.m 11.07.2lbl4rl
SELF-LOCKING NUTl0 x 1.25 mm
3:t N.m {3.4 kgf m,24lbf'ftl
ReDlace.PRIMARY IIEATEDOXYGEN SENSOR{PRIMARY HO2S)ll N.m (4.5 kgl.m,33 tbt f0Replacement,
SECONDARY HEATEDOXYGEN SENSOR{SECONDARY HO2SIlrt N.m 14.5 kgf.m,33 rbl.ft)Replacement, page 9-13
GASKETR€place.
twcInspection, page 9-12GASKEISReplace.
SELF.L(rcKNG NUT10 x 1.25 mm5,r N.m 15.5 kgf.m, ,|{} lbf.ft)ReDlace.
8x1.25mm22 N.m {2.2 kgt m, 16 lbf.ftlReplsce.Tight6n the bolts in st6ps,alternating side-to-side.8 x 1.25 mm16 N.m 11.6 kgt.m,12 rbf.ft)F€pl8ce.
I
Replaca.
9-11

TWCHO2S
Inspection
l. Using a flashlight, make a visual check for plugging,
melting and cracking of the catalyst.
D16Y5, D16Y7 engines:
816A2, D16Y8 engines:
-\6{-)\
lT
a
A
FLASHLIGI{T
9-12
Replacement
Primary HO2S:
1. Remove the primary HO2S.
D16Y5, D15Y7 engines:
a. Disconnect the primary HO2S connector, thenremove the cover.
8 x'1.25 mm24 N.m {2.4 kgl.m,
PRIMARY H02SCONNECTOR
b. Remove the primary HO2S.
| \l ,l(
I bK/l
l llw.
/
(
PBIMARY HO2S44 N m (4.5 kgf.m, 33 tbI.ft)