head light HONDA CIVIC 1999 6.G Workshop Manual

ITEMMETRICENGLISHNOTESTEERINGSYSTEMTvpe P/sM/SOverall Ratio p/S
M/STurns, Lock-to Lock p/S
M/SSteering Wheel Dia.
Power assisted, rack and pinionRack and pinion1l.120.33.64..1380 mm 15.0 inSUSPENSIONTYPe Front and RearFront and RearIndependent double wishbone, coil springTelescopic, hydraulic nitrogen gas-filled
WHEELALIGN| 4ENTCamber FrontRearCaster F.ontTotalToe FrontRear
0.00,- 't'
1.40'ln 1 mm ln 1/16In 2 mm In 1/16EBAKE SYSTEMType FrontRea r
Pad Surface Area Front
Rea r
Parking Brake Type
Power assisted self adjusting ventilated discPower assisted self adiustjng solid discPower assisted sell adjusting dr!m37.5 cm'x 4 5.8 sq in x 4
44.1ctn,x4 ] 6.84sq-inxa
67.2 cmz x 4 | to.+ sq in ' I21.2 cm, x 4 3.3 sq in x 4Mechanical actuating, rear two wheelbrakes
5410 stamped onthe caliper body2056 stamped onthe caliper bodyDrumDisc
TIRESize and PressureSee lire intormation label
WASHERCapacity 2door Coupe/4,door Sedan
2,door Hatchback
2.5 f (2.6 LJS qt, 2.2 lmp qt)4.5 | (4.8 US qt,4.0lmp qt)2.51 (2.6 US qt, 2.2 lmp qt)4.5 f (4.8 US qt, 4.0 lmp qt)
USA modelCanada modelDXExcept DXELECTRICALBafteryStarterAlternatorFuses In Under dash Fuse/Felay BoxIn Under-hood Fuse/Belay 8oxIn Under hood ABS FLrse/Relay BoxHeadlightsFront Turn Signal/Parking LightsRear Turn Signal LaghtsBrake/TaillightsInner Taillights*,High Mount Brake LightBack up LightsLicense Plate LightsCeiling Light
Trunk LightsGauge LightsIndicator Lightslllumination and Pilot LightsHeater Control Panel Lights
12 V 38 AH/5 HR12 V 1.0 kW, 1.2 kW12V 75 A,80 A7.5 A, t0 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A, 80 A7.5 4.20 A, 40 A12V_60/55W12V -2115W
12V - 21W12V - 21/5W12V-5W12 V 18 W*" 21 W+" *3
12V 21W12v-5wl2V-8W(Withmoonroofl12 V - 5W (Without moonroof)
12V-1.4W,3W't2 v 1.12W. 1.4 W12v-0.84w, 1.4 W12V 1.4 W
Design Specifications
(cont'd)
P/S: Power Steering M/S: Manual Steering*l: 2-door Coupe *2: 2door Hatchback *3: 4-door Sedan*4: USA (HAM), Canada (HCM) produced *5: Japan produced
3-22
L'

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.

Valves
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
Installation (cont'd)
4. Install the valve spring and valve retainer. then
install the valve spring compressor. Compress the
spring and installthe valve keepers.
NOTE: Place the end of the valve spring with close-
ly wound coils toward the cylinder head.
lCornmercially available)Snap-on CFrll or KD - 3tX'with #32 JAWS
Lightly tap the end of each valve stem two or three
times with a plastic mallet to ensure proper seating
of the valve and valve keepers.
NOTE: Tap the valve stem only along its axis so you
do not bend the stem.
' 6-44
Installation
CAUTION:
. Make sure that all tockers are in alignment with their
valvgs when torquing the rocket assembly bolts,. Valve locknuls should be loosened and adiusting
screws backed off bofore installation.
. To prevont tho rocker arm a$smbly from coming
apad, l6av€ the camshaft holder bohs in the holdeB.
1. After wiping down the camshaft, camshaft seal andjournals in the cylinder head, lubricate both sur-
faces and install the camshaft.
2. Clean and install the oil control orifice with a new
O-ring.
CAMSHAFT SEALSeal housing surface should be dry.Apply a light coat of oil to camshaftand inner lip of seal.
3. Turn the camshaft until its keyway is facing up (No.
piston TDC).
OIL CONTROL ORIFICE

11. 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
(top of the semicircles)
Set the spark plug seal on the spark plug tube.
Once the cylinder head cover is on the cylinder
head, slide the cover slightly back and forth to seat
the head cover gasket.
NOTE:
. Before installing the cylinder head cover, clean
the cylinder head contacting surfaces with a
shop towel.
. Do not touch the parts where liquid gasket was
aDolied.
. Take care not to damage the spark plug seals
when installing the cylinder head cover,
. Visually check the spark plug seals for damage.
. Replace any washer that is damaged or deterio-
rated.
6x1.0mm9.8 N.m 11.0 ksf.m,7.2lbf ftl
\g-----*o""t'Ptl
veEE
\_
6-47
12. Tighten the nuts in two or thre€ steps. In the final
step, tighten all bolts, in sequence, to 9 8 N'm (1.0
kgf.m, 7.2 lbf.ft).
NOTE: After assemblv, wait at least 30 minutes
before filling the engine with oil
After installation, check that all tubes, hosss and
connectors are installed correctlY
1?

Valve Glearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylinder
head temperaturs is less than 100'F (38'C)'
. After adjusting, retorque the crankshaft pulley bolt to
177 N.m (18.0 kgf'm, 130 lbt'ft)
1. Remove the cylinder head cover'
NOTE: Refer to page G86 when installing the cylin-
der head cover.
2. Set No. 1 pi$on at TDC. The "UP" mark on the pullsy
should be at the top, and TDC grooves on the pulley
should align with the pointer on the back cover' TDC
grooves {white paint) on the crankshaft pulley should
align with the pointer on the timing belt lower cover'
Number I Piston at TDC:
4.
Adjust valves on No. 1 cylinder.
lntako: 0.15 - 0.19 mm {0'006 - 0.007 in)
ExhaGt 0.17 - 0.21 mm {0'007 - 0 008 inl
Loosen the locknut, and turn the adjusting screw
until the feeler gauge slides back and forth with a
slight amount of drag.
TAPPET ADJUSTERWFENCH SET07MM - PR70110
TAPPET LOCKNUTWRENCH07MAA - PR70120
Adiusting sclaw location:
LOCKNUT20 N.m {2.0 kgf'm, lil lbt'ftl
(cont'd)
6-57

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.
(

Valves
1.
Installation
Coat the valve stems with oil. lnsert the valves into
the valve guides.
NOTE: Check that the valves move up and downsmoothly.
Installthe spring seats on the cylinder head.
Install the valve seals using the special tool.
NOTE: Exhaust and intake valve seals are not inter-
changeable.
WHITESPRING
VALVE GUIDE SEAL INSTALLERKD-28)g (Commercially available)NOTE: Use small lDend of tool,
2.
BRACKSPRING
VALVE SEALReplace.
tNsTALLERVALVE GUIDE SEALKD-2899NOTE: Use small lDend of tool
(
4. lnstall the valve spring and valve retainer, theninstall the valve spring compressor. Compress thespring, and install the valve keepers.
NOTE: Place the end of the valve spring with closely
wound coils toward the cylinder head.
VALVE SpRtNG VALVE SPRTNG
COMpRESSOR COMPRESSORATTACHMENT
ATTACHMENT EXTENSTON
0775? _ pJlOl0A o?MAF - PR9010A
VALVE SPRING COMPRESSORlCommercially available)Snap-on CF711 or KD-3tXlwith #32JAWSLightly tap the end of each valve stem two or threetimes with the wooden handle of a hammer to ensureproper seating of the valve and valve keepers.
NOTE: Tap the valve stem only along its axis soyou do not bend the stem.
I
5.

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.

Cylinder BlockPiston Pins
Bore Honing
1.Measure cylinder bores as shown on page 7-16. lf the
block is to be reused, hone the cylinders and remea-
sure the bores.
Hone cylinder bores with honing oil 8nd a fine (400
grit) stone in a 60 degree cross-hatch pattern.
NOTE:
. Use only a rigid hone with 400 grit or finer stone
such as Sunnen, Ammco, or equivalent.
. Do not use stones lhat are worn or broken.
When honing is complete, thoroughly clean the
engine block of all metal particles. Wash the cylin-
der bores with hot soapY water, then dry and oil
immediately to prevent rusting.
NOTE: Never use solvent. it will only redistribute the
grit on the cylinder walls.
lf scoring or scratches are still present in cylinder
bores after honing to the service limit, rebore the
cylinder block.
NOTE: Some light vertical scoring and scratching is
acceptable if it is not deep enough to catch your fin-
gernail and does not run the full length of the bore.
CYLINOES BLOCK
CYLINDER
NOTE:
. After honing, clean the cylinder thoroughly with
soapy warer.
. Onlv a scored or scratched cylinder bore must be
noneo.
Removal
l. Assemble the special tool as shown.
PISTON BASE HEAD07973 - SBtx)too
ft
PISTON PIN BASE
INSERT01973 - PE00'0)
ptn
NOTEi Us6 a hydraulic press.When pressing the pin in or out.make sure that the recesssdportion of the piston alignswith the lips on the collar.
rg
g\
lj*N*,""
2. Assemble and adjust the length of the piston
driver and shaft to 53 mm (2.1 inl as shown.
PISTON PIN DRIVER HEAD07973 - PE00320
Proat
0
PISTON PINDRIVER SHAFT0t973 - PEqr310
PILOT COLLAR07973 - PE00200
3. Place the piston on the sp€cial tool and press the
pin out with the special tools and a hydraulic press.
Emboss6d mark facing up
7-17

ECM/PCM CONNECTOR D I16P)
Wire side ot female terminals
ECM/PCM CONNECTOR D l16P)NOTE: Standard battery voltage is 12 V
Te.minalnumb€r
Wirecolor
Terminaln!meDor.riptionSignal
RED/BLKTPS (THROTTLE POSITION
SENSOR}
Detects TP sensor signal.With throttle fully open: about 4.8 V
With throttle fully closedl about 0.5 V
REDA/VHTECT {ENGINE COOLANTTEMPERATURE SENSORDetects ECT sensor signalWith ignition switch ON{ll): about 0.1 - 4 8 v
(depending on engine coolant lempe ratu re)
3RED/G RNMAP {MANIFOLD ABSO'LUTE PRESSURE SENSOR}Detects MAP sensor signal.With ignition switch ON(ll): about 3 V
At idle: about 1.0 V
{depending on engine speed)
YEUREDVCCl (SENSOR VOLTAGE)Power source lor MAP sensor.With ignition switch ON (ll): about 5 v
With ignition switch OFF: 0 V
5GRNMHTBKSW {BRAKE SWITCHIDetects brake switch signalWith brake pedal released: 0 v
With brake pedal depressed: baftery voltage
6*?RED/BLUKS {KNOCK SENSOR}Detects KS signal.With engine knocking: Pulses
1
PHO2S (PRIMARY HEAT-ED OXYGEN SENSOR,SENSOR 1)
Detects Primary heated oxygen
sensor (sensor 1l signal
With throttle fullv opened from idle with
Iully warmod up engine: above 0.6 V
With throttle quickly closed: below 0.4 v
LABELDetects LABEL resistanceWith engine r!nning:about 0.3 - 4.9 V
8RED//ELIAT (INTAKE AIR TEM-PERATURE SENSOR)
Detects IAT sensor signal.With ignition switch ON (ll): about 0 1 -
4.8 V {depending on intake air temperature)
9*lWHT/BLKEGRL iEGR VALVE LIFT
SENSOR)
Detects EGR valve lift sensor signalAt idle without vacuum: about'1 2 V
With 27 kPa (2OO mmHg,8 in. Hg): about 4 3 V
10YEUBLUVCC2 (SENSOR VOLTAGE)Provides sensor voltage,With ignition switch ON(ll): about 5 V
With ignition switch OFF:0 V
11GRN/BLKSG2 (SENSOR GROUND}Sensor ground.Less than 1.0 V at alltimes
12G RN,4/1r'HTSG1 (SENSOR GROUND)Ground for MAP sensor.Less than 1.0 V at alltimes
GRN/BLK*1?SHO25G (SECONDARY
HEATED OXYGEN SEN'
SOR, SENSOR 2 GROUND)
Ground for secondary heated oxy-
gen sensor (sensor 2).
14WHT/REDSH02S (SECONDARY
HEATED OXYGEN SEN'soR, sENsoR 2)
Detects secondary heated oxygen
sensor (sensor 2) signal.With throftle fully opened lrom idle with
fully warmed up engine: above 0.6 V
With throttle quickly closed: below 0.4 V
15|3. *15LT GRNPTANK {FUEL TANK PRES.
SURE SENSOR)
Detects fueltank prgssure sensor'With fuelfill caD opened: about 2.5 V
16*1GRN/RED
EL (ELD)Detects ELD signal.With parking lights turned on at idle: about
2.5 - 3.5 VWith low beam headlights turned on at
idle: about 1.5 - 2.5 V
*1: USA model*2r A/T (D16Y7, D16Y8 engine)*3: CVT (D16Y5 engane)*4: A,/T and Dl6Y7 engine*5: Except A/T and D16Y7 engine*6: A"/T (D16Y8 engine)i7: CVT (Dl6Y5 engine) and Dl6Y8 engine*8: .96 D16Y8 engine (coupei,'97 D16Y8 engine
models, sedanr KL model),'98 016Y5 engine,
engine, '99 - 00 D16Y5 (M/T) engine
*9: D16Y5 engine*10: M/T (D16Y5 engine)*11: Except M/T (Dl6Y5 engine)* 12r D16Y5. D16YB engine*13: D16Y8 engine*14: Dl6W engine*15: '97 D16Y7 engine (coupe: KL model, sedan: KL lLX) model),'98D16Y7 engine:(coupe: all'98 D16Y8
(cont'd)
1 1-91