Acc HONDA CIVIC 2000 6.G User Guide

Timing Belt
Removal
NOTE:
. Replace the timing belt at 105,000 mites (168,000 km)according to the maintenance schedule (normal con-ditions/severe conditions).
lf the vehicle is regularly driven in one or more of thefollowing conditions, replace the timing belt at 60,OOOmiles (U.S.A.) 100,000 km {Canada).. In very high temperatures (over 110"F, 43"C).. In very low temperatures (under -20.F, 29.C).. Turn the crankshaft pulley so the No. 1 piston is attop dead center (TDC) before removing the belt (seepage 6-57).
. Inspect the water pump before installing the timingbelt {see page 10-14).
1.
IOLER PULLEY BRACKETEOLT10 x 1.25 mm44 N.m 14.5 kgf.m, 33 bnft)
6-62
Remove the splash shield (see page 5-9).
Remove the adjusting bolt and mounting bolts, thenremove the power steering (P/S) pump belt andpump.
8xL25mm24 N m {2.{ kgf.m, 17 lbf.ft)
Loosen the idler pulley bracket bolt and adjusting bolt,then remove the air conditioning (A,/C) compressorbelt aDJUsnNG
44 N.m 14.5 kgt.m, 33 lbf.ft)
P/S PUMP LOWER ARACKET
a\
4. Loosen the mounting nut and lock bolt, then removethe alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgt.m.17 rb{.ftl
5. Remove the upper bracket (see page 6-69).
NOTE:
. Use a jack to support the engine before removingthe upper bracket.
o Place a cushion between the oil pan and the jack.
Remove the P/S pump lower bracket
8 x 1.25 mm24 N.m 12.,1 kgf.m,17 tbf.ftl
l0 x 1.25 mm
'-f'
MOUNTING10 x 1.25 mm44 N.m (4.5 kgf.m.33 rbf.fttBELT
HEAT SHIELD

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.
(

Main Bearings
4.
Glearance
1.To check main bearing-to-journal oil clearance.
remove the main caps and bearing halves.
Clean each main journal and bearing half with a
clean shop towel.
Place one strip of plastigage across each main jour-
na l.
NOTE: lf the engine is still in the car when you bolt
the main cap down to check clearance, the weight
of the crankshaft and flvwheel will flaften the plasti-
gage further than just the torque on the cap bolt.
and give you an incorrect reading. For an accurate
reading, support the crank with a jack under the
counterweights and check only one bearing at a
time,
Reinstall the bearings and caps, then torque the
bolts.
lst step: 25 N'm (2.5 kgl'm. 18 lbf'ft)
FinalsteD:
B16A2 engine:
76 N.m (7.8 kgf.m, 56 lbf'ft)
D16Y5, Dl6Y7, D16Y8 engines:
51 N.m (5.2 kgf'm, 38 lbf'ft)
NOTE: Do not rotate the crankshaft during inspec-
tron.
Remove the cap and bearing again, and measure the
widest part ot the plastigage.
Main Boaring-toJournal Oil Clearance:
816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l - 0.042 mm 10'00(B - 0.0017 in)
No. 3 Journals:
0.030 - 0.048 mm {0'0012 - 0'0019 in)
Servico Limit: 0.06 mm {0.002 in,
Dl6Y5, Dl6
r, Dl6Y8 engines:
Standard (Nsw):
No. 1,5 Journals:
0.018 - 0.035 mm {0.0007 - 0'001'[ in)
No. 2. 3, 4 Journals:
0.02,1 - 0.0,(2 mm {0'0009 - 0.0017 in}
Service Limit: 0.05 mm (0.002 in)
\
7-9
7.
lf the plastigage measures too wide or too narrow,
(remove the engine if it's still in the car), remove the
crankshaft, and remove the upper half of the bear-
ing. Install a new. complete bearing with the same
color code {select the color as shown on the next
page), and rechsck the clearance.
CAUTION: Do nol fil€, shim, or scrape the bearings
or tho cap3 to adiust cleatanc€.
lf the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color
listed above or below that one), and check again
NOTE: lf the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

Main Bearing
Selection
CAUTION: lf the codes are indecipherable because of anaccumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent ol
deiergent.
Crankshaft Bore Code Location
81642 engine:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers or bars stamped on the
crank {codes for main journal size), to choose the correct
beaflngs.
Main JournalCode Locations {Nombers or Barc)
Eearing ldentificationColor code rson lhe edge ofthe bear ng.Larger crank bore
acD
-----------""' Smallerbeanngtlhrcker)
9""1B':""
Alack
Black
Alue
7-10
\
D16Y5, D16Y7, D16Y8 engines:
Letters have been stamped on the end of the block as acode for the size of each of the 5 main journal bores.
Use them, and the numbers stamped on the crankshaft(codes for main journal size), to choose the correct bear-
Ings.
Main Journal Code Location (Numbers)
\
Color codeon theedge ofthe bearing-
Ldrger crank bore
Smaller bea ng {th'cker)
lr-l
t#lt+,tlf l 4 tlf '- 't
Smaller Smallermaan bearingjournal {thicker)
RedPinkGreen
PinkGreenBrown
GreenBrownBlack
GreenBrownBlackElue
I
Bearing ldentification
BcD

Connecting Rod Bearings
Clearance
Remove the connecting rod cap and bearing half
Clean the crankshaft rod iournal and bearing half
with a clean shop towel.
Place plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the nuts.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and bearing half and measure
the widest part of the plastigage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engine:
Standard lNewl: 0.032 - 0.050 mm
10.0013 - 0.0020 in)
Service Limit: 0.06 mm 10.002 inl
D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 0.020 - 0.038 mm
(0.0008 - 0.0015 in)
Service Limit 0.05 mm 10.002 inl
'1.
4.
lf the plastigage measures too wide or too narrow'
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
the color as shown in the right column), and
recheck the clearance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf the plastigage shows the clearance is still incorrect.
try the next larger or smaller bearing (the color listed
above or below that one), and check clearance again.
NOTE: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
PLASTIGAGE STRIP
\
7.
7-11
Selection
CAUTION: lf the codes are indecipherable because of
an accumulation of dirt and dust, do not sclub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the side of each con
necting rod as a code for the size of the big end Use
them, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearlngs
Half of number ls
stamped on bearingcap and the otherhalf is stamped onrod.
Bearing ldentilication
Color code is on theedge ofthe bearing.
lfA--;T] |
lle"'tt l;llcorlll ll
I lD;;ilril |l-l
Larger brg end bore
Smaller Smallerrod bearlngjournal (thicker)
---------------- Smallerbearing{thrcker)
RedPinkGreen
PinkGreen
GreenErownBlack
GreenBrownBlackBlue
1234
Connecting Rod Journal Code Locations (Lettels)

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

RequirementAPI Service Grade: Use an "Energy
Conserving" SJ grade oil or an"Energy Conserving ll" SH grade oil,
SAE 5W - 30 preferred
You can also use an oil that bears the
API CERTIFICATION mark.
Capacity[atolz engine:
3.7 f (3.9 US qt,3.3 lmp qtl
I at oil change.
J 4.0 r 9.2 US qt, 3.5 lmp qtl
I at oil change, including filter'
| 4.8 f (5.1 Us qt,4.2 lmp qt)
I after engine overhaul
I Dl6Y7 engine:
3.6 f (3.8 US qt, 3.2 lmP qt)
I at change. including filter.
I 3.3 f (3.5 US qt,2.9 lmP qtl
I at change, without filter.
I 4.3 f (4.5 us qt,3.8 lmp qtl
I after engine overhaul.
J D16Y5, D16Y8 engines:
L 3.3 { {3.5 US qt,2.9 lmp qt}
I at change, including filter.
3.01 (3.2 US qt,2.6lmp qt)
I at change, withoutfilter.
3.7 { (3.9 US qt,3.3 lmp qt}- '1.€fter engine overhaul.
ChangeEvery 7,500 miles (12,000 km) or
12 months (Normal Conditions).
Every 3,750 miles (6,000 kml or
6 months (Severe Conditions).
3. Reinstall the drain bolt with a new washer. and rbfill
the engine with the recommended oil.
NOTE: Under normal conditions, the oil filter should be
replaced at every other oil change Under severe condi-
tions, the oilfilter should be replaced at each oil change'
The numbers in the middle of the API Service label tell
you the oil's SAE viscosity or weight Select the oil for
vour car according to this chart:
30 20 -10 010 20 30 4OoC
An oil with a viscosity of 5W - 30 is preferred for
improved tuel economy and year-round protection in the
car. You may use a 10W - 30 oil if the climate in your area
is limited to the temperature range shown on the chart'
Ambient Temoerature
API CERTIFICATION MARK
API SERVICE LABEL
Run the engine tor more than three minutes, then
check for oii leakage
8-7

EGT Switch
-f
Testing
Replace the thermostat if it is open at room temperature'
To test a closed thermostat:
1, Suspend the thermostat in a container of water as
shown.
THEBMOMETER
THERMOSTAT
Heat the water, and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens, and at which it is fully open
CAUTION: Do not let the thermometer touch the
bottom of the hot Gonlainel.
Measure lift height of the thermostat when fully
open.
STANDARD THERMOSTAT
Lift height above 8.0 mm (0.31 inl
Starts opsning: 169' - 176'F (76' - 80'Cl
Fully open: 194'F {90"C1
!'o
10-1 1
Testing
!!@ Romoving the EcT swhch while lhs engine
i!-ot can cause the coolant to sPray out, seriously scald-
ing you. Always lst th€ ongine and rediator cool down
before removing ihe ECT switch.
NOTE: Bleed air from the cooling system after installing
the ECT switch (see Page 10-7)
1. Remove the ECT switch from the thermostat hous-
ing (see Page'10-10).
2. Suspend the ECT switch in a container of water as
shown.
Heat the water, and check the temperature with a
thermometer.
CAUTION: Do not let the thermomoter touch tho
bottom of the hot container'
Measure the resistance between the A and B termi-
nals according to the table.4.
Terminal
Oo"rffi
swlTcH
ON196' - 203"F
(91" - 95'C)o--o
OFF
5" - 15'F {3" - 8'C)
lower than the temPera-
ture when t goes on

lf the inspection for a particular code requires voltage or resistance checks at the ECM/PCM connectors, remove the right
kick panel. Pull the carpet back to expose the ECM/PCM. Remove the ABS control unit if so equipped. unbolt the EcM/
PCM bolt. Turn the ignition switch oFF, and connect the backprobe sets and a digital multimeter as described below
check the system according to the procedure described for the appropriate code(s) listed on the following pages'
The illustrationshows '96 - '98 models.
How to Use lhe Backprobe Sets
connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. using the wire insula-
tion as a guide for the contoured trp of the backprobe adapter. gently slide the tip into the connector from the wire side
until it comes in contact with terminal end of the wire'
BackProbe
BACKPROEE SET
07SAZ - 001000A lTwo
DIGITAL MULTIMETER(Commercially avail.bleI orKs - AHM - 32 - oo3 (cont'd)
KICK PANEL
1 1-83

Troubleshooting
Troubleshooting Procedures (cont,dl
ECM/PCM Data
By connecting the OBD ll scan tool or the Honda pGM Tester to the l6p data link connector (DLC), various data can beretrieved from the EcM/PcM. The items Iisted in the table below conform to the sAE recommended practice.The Honda PGM Tester also reads data beyond that recommended bv SAE.understanding this data wil help to find the causes of intermittent fairures or engine probrems,
NOTE:
' The "operating values" given below are approximate values and may be different depending on the environment andthe individual vehicle.. Unless noted otherwise, "at idle speed,, means idling with the engine completely warmed up, Ay'T in position @ or E],M/T in neutral, and the Ay'C and all accessories turned off.
(
DataDescriptionOperating ValueFreeze Data
Diagnostic
Trouble Code(DTC)
lf the ECM /PCM detects a problem, it will store it as acode consisting of one letter and four numbers.Depending on the problem, an SAE-defined code (poxxx)or a Honda-defined code (Plxxx) will be outDut to therester.
lf no problem is detected,
there is no output.
YES
Engine SpeedThe ECM/PCM computes engine speed from the signalssent from the Crankshaft Position sensor.This data is used for determining the time and amount offuel injection,
Nearly the same as
tachometer indication.YES
Vehicle SpeedThe ECM/PCM converts pulse signals from the VehicleSpeed Sensor (VSS) into speed data.Nearly the same as
speedometer indicationYES
Manifold
Absolute
Pressure {MAP)
The absolute pressure caused in the intake manifold bvengine load and speed.With engine stopped:
Nearly the same as atmo-
spheflc pressure
At idle speed:
24 - 31 kPa (180 - 280
mmHg, 7.1 - 11.0 inHg)
YES
Engine Coolant
Temperature
(ECT)
The ECT sensor converts coolant temperature into volt_age and signals the ECM/PCM. The sensor is a thermistorwhose internal resistance changes with coolant temDera_ture. The ECM/PCM uses the voltage signals from theECT sensor to determine the amount of iniected fuel.
With cold engine:
Same as ambient temper,
ature and IAT
With engine warmed up:
176 - 194.F (80 - 90.C)
YES
Heated Oxygen
Sensor {HO2S)(Primary,
Sensor 1)(Secondary
Sensor 2)
The Heated Oxygen Sensor detects the oxygen contentin the exhaust gas and sends voltage signals to theECI\4/PCM. Based on these signats, the ECM/pCM con_trols the airlfuel ratio. When the oxygen content is high(that is, when the ratio is leaner than the stoichiometricratio), the voltage signal is lower.When the oxygen content is low (that is, when the ratiois richer than the stoichiometric ratio), the voltage signalis higher.
0.0 - 1.25 V
At idle speed:
about 0.1 - 0.9 V
NO(Sensor 1)
1 1-86