Air con HONDA CIVIC 2000 6.G User Guide

(From page 6'4)
Test the VTEC Solenoid Valve:1. Turn the ignition switch OFF.2. Disconnect the wEC solenoidvalve 1P connector.3. Attach the battery positave
terminal to the VTEC solenoidvalve terminal.4. Start the engine and checkthe oil pressure at enginespeed of 5,000 rpm.
Inspect lhe VTEC solonoid valve
lsee p6ge m).ls the pressure above 390 kPa(4.0 kgtcm',57 psi)?
Test the VTEC Pressure Switch:With the battery positive terminalconnected to the VTEC solenoidvalve, measure voltage betweenthe ECM/PCM connector terminal'96 - 98: Cl5,'99 - 00: C10 andbody ground.
ls there battery voltage above5,000 rpm?
T6st the VTEC Solenoid Valvewire:1. Turn the ignition switch OFF.2. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal and theECM/PCM connector terminal'96 - 98: A8, '99 00r B'12.
Repair open in the wire betweenthe ECM/PCM ('96 - 98: A8, '99 -
0o: 8l2l and VTEC solenoid v.lv6connoc{or.
Test the VTEC Solenoid Valve
Check for continuity between theVTEC solenoid valve 1P connectorterminal €nd body ground.
ReDair 3hort in the wire betweenthe ECM/FCM ('96 - 98: A.8, '99 -
0O: Bl2l and VTEC aolenoid valveconnectot,
ls there continuity?
Substitute a known-good ECM/PCM and recheck. lf symptom/indication goes away, replacethe original ECM/PCM.
VTEC SOLENOID VALVE1P CONNECTOR
Terminalside ofmale terminal
ECM/PCM CONNECTOR C {31P}
'99 - 00:'96 - 98:
CONNECTOR
'99 - 00:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTORB {25Pt1P CONNECTOR'96 - 98:
VTEC SOLENOIDVALVE
ECM/PCM CONNECTOR
A {32P1
VTS{GRN/YEL)
wire side o{ femaleterminals
wire side oI temaleterminals
VTM

VTEC Rocker Arms
Inspection Using SpecialTools (Dl6Y5 enginel
CAUTION:
. Before using th6 Valve Inspection Tool, make 3ure
that ths air pressure gaugo on the air comptsssor
indicates over iloo kPa 14 kgf/cmr, 57 psi).
. Inspecl th6 valv€ clearance beforo rocker atm insDec"
tion,
'1.
Cover the timing belt with a shop towel to protect tho
belt.
Check ths intakg primaty rocker arm of each cylindqr atTDC.
Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylin-
der head cover.
Plug the relief hole with the special tool.
YY
OTLAJ - PR3O2OB
(
3, Remove the sealing bolt from the inspection holeand connect the an air pressure regulator with a 0 -
100 psi gauge.
10 x 1.0 mmSEALING BOLT20 N.m {2.0 kgj'm. 14lblft}
l
I
'10 x 1.0 mmADAPTER;NSp€CTTONHOLE (Commercially
available)
l'Pullthe dial andturn to adlust,
Loosen the regulator valve on the valve inspection
tool and apply the specified air pressure.
Spocified Air Pressurei
250 kPa {2.5 kg,t/cm,,36 psi}
o-at

5. With the specified air pressure appli€d, push up the
timing plate; the synchronizing piston will pop out
and engage the intake secondary rocker arm.
Visually check the engagement of the synchronizing
prston.
NOTE;
The synchronizing piston can be seen in the gap
between the secondary and primary rocker arms,
With the timing plate engaged in the groove on
the timing piston, the piston is locked in the
oushed out Dosition.
TIMIiIGPLATESPRIT{C
PRIMARY ROCKER ARM
AIR PRESSURE
GROOVE
SECO DARYROCKER ARM
TIMIT{G PLATE
TIMING SPRING
6-9
6. Stop applying air pressure and push up the timing
plate; the synchronizing piston will snap back to its
original position.
Visually check the disengagement of the synchro-
nizing pistons.
NOTE:
. When the timing plate is pushed up, it releases
the timing piston, letting the return spring move
the synchronizing piston to its original position.
7. Replace the intake rocker arms as an assembly if
either does not work correctly,
TIMING PLATE
oll PASSAGE --!
PRIMARY ROCKER
ARMSECOI{DARYROCKER ARM
TIMII{G SPRII{GRETURI{ SPRING
Remove the spscial tools.
After inspection, check that the malfunction indicator
lamp (MlLl does not come on.
TIMI G PISTOI{

VTEC Rocker Arms
Inspection Using Special Tools (D16Y8 enginel
CAUTION:
o Before using the Valve Inspection Tool. mak6 surethat the air pressure gauge on the air comprsssor
indicates ovor 400 kPa {4 kgf/cm,, 57 psil.
. Inspect th6 valve clearanco before rockar arm inspec-
tion.
. Cov€r th€ timing belt with a shop towel to protect
the bolt.
. Check tho intake prima.y rockff arm of each cylindel
at TDC.
1.Remove the cylinder head cover.
NOTE: Refer to page 6-46 when installing the cylinder
neao cover,
Plug the relief hole with the specialtool.
OTLAJ - PR3O2OB
I,^ A IAo- tu
3. Remove the sealing bolt from the inspection hole
ancl connect an air pressure regulator with a 0 - 100psi gauge.
l0 x 1.0 mmSEALING EOLT20 N.m (2.0 kgf.m, 14 lbf.ft)
(AIR PRESSUREREGULATOR
{Commerciallyavailable). Pullthe dialandturn to adjust,

4. Loosen the regulator valve on the valve inspection
tool and apply the specified air pressure.
Specified Air Pressure:
250 kPa {2.5 kgf/cm', 36 psil
PRIMARY ROCKERARM
SYNCHRONIZING SYNCHRONIZINGPISTON A PISTON B
Make sure that the intake primary and secondary
rocker arms are mechanically connected by the piston
and that the mid rocker arm does not move when
oushed manuallY.
5.
MID ROCKER SECONDARYARM ROCKER ARM
SECONDARYROCKER ARM
lf any intake mid rocker arm moves independently of
the primary and secondary rocker arms, replace the
rocker arms as a set.t
1.
8.
9.
Remove the special tools.
Use a 10 mm diameter rod to depress each lost
motion assembly through its full movement.
Replace any lost motion assembly that does move
smoothly.
After inspection, check that the MIL does not come
on.
ASSEMBLY
6-11

Removal
NOTE:
. Replace the timing belt at 105,000 miles (168.000 km)
according to the maintenance schedule (normal con-
ditions/severe conditions).
lf the vehicle is regularly driven in one or more of the
followlng conditions, replace the timing belt at 60.000
miles (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 at
top dead center (TDC) before removing the belt (see
page 6'21).
. Inspect the water pump before installing the timing
belt {see Page 10-14).
1. Remove the splash shield (see page 5-7).
2. Loosen the mounting bolt and lock bolt. then remove
the power steering (P/S) pump belt and pump
MOUNTING BOLT
8 x 1.25 mm2il N m 12.4 kgl m, 17 lbf'ft)
P/S PUMPBELT
I x 1.25 mm24 N m (2.4 kgf m, 17 lbt ft)
Loosen the idler pulley center nut and adjusting
bolt, then remove the air conditioning (AVC) com-
pressor belt (see Page 5-6).
Loosen the mounting nut and lock bolt, then remove
the alternator belt.
ALTERNATORBELTLOCK BOLTI x 1.25 mm24 N.m 12.4 kgf.m,r? tbI.ft)
3.
MOUNTING NUT10 x 1.25 mm44 N.m 14.5 kgl m,
33 rb{ ft)
5. Remove the dipstick, then remove the upper cover
and idler PulleY bracket
NOTE: Do not use the upper cover to store removed
items.
6x1.0mm9.8 N.m 11.0 kgf.m,7.2
IDLERI x 1.25 mm24 N.m (2.4 kgl.m, 17 lbf'ft)BRACKET
6. Remove the upper bracket {see page 6-29)
NOTE:
. Use a jack to support the engine before the upper
bracket is removed
. Make sure to place a cushion between the oil
pan and the jack.
Remove the crankshaft pulley (see page 6-16).
Remove the lower cover and dipstick tube
NOTE; Do not use the lower cover to store removed
items.
1.
.'.
DIPSTICK TUBE
LOWER
6x1.0mm9.8 N.m (1.0 kgf m,
7.2 rbt.ft)
(cont'd)
6-19
Replace.

Removal
Engine removal is not required for this procedure
!!!s@ Make sure iacks and salety stands are
f ta"eata"ea propetty and hoist brackets are attached to the
correct positions on the engine.
CAUTION:
. Use tender covels to avoid damaging painted sul-
faces.
o To avoid damage, unplug the wiling connectors
carefully while holding the connector portion to
avoid damage.
. To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F
{38"C} before loossning the tetaining bolts.
NOTE:
o Mark all wiring and hoses to avoid misconnectlon
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
. Inspect the timing belt before removing the cylinder
h ead.
. Turnthe crankshaft pu lley so that the No. lpistonisat
top dead center (see Page 6-21)
'1. Disconnect the negative terminal from the battery'
Drain the engine coolant (see page'10-7).
a Remove the radiator cap to speed draining.
Remove the intake air duct and air cleaner housing
(see page 5 3).
Remove the mounting bolt and lock bolt. then
remove the power steering (P/S) pump belt and
pump (see page 5'5).
Loosen the idler pulley center nut and adjusting
bolt' then remove the air conditioning (A'lc) com-
pressor belt (see Page 5-6).
Loosen the mounting nut and lock bolt. then
remove the alternator belt (see page 6-19).
Remove the P/S pump bracket (see page 5-12).
3.
4.
2.
6.
1.
8. Remove the throttle cable by loosening the locknut,
then slip the cable end out of the throttle linkage
NOTE:
. Take care not to bend the cable when removing it
Always replace any kinked cable with a new one
. Adjust the throttle cable when installing (see sec-
tion 1 1).
D16Y7 engine:
Dl6Y5, Dl6Y8 engines:
THFOTTLECABLE
(cont'd)
6-27
LOCKNUT
CABLE

13. Remove the upper radiator hose' heater hose and
water bYPass hose
WATEREYPASSHOSEUPPERRADIATORHOSE
14.
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
nector
a
a
a
ECT switch connector
ECT gauge sending unit connector
Throttle position sensor connector
Manitold absolute pressure (MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
Secondary heated oxygen sensor (secondary
HO2S) connector (D16Y7 engine)
Exhaust gas recirculation (EGR) valve lift sensor
connector (D16Y5 engine)
. VTEC solenoid valve connector (Dl6Y5, D16Y8
engrnes)
. VTEC pressure switch connector (D16Y5. D16Y8
engrnes,
. ldle air control (lAC) valve connector
15.Remove the spark plug caps and distributor from
the cylinder head.
Remove the uPPer bracket.
NOTE:
. Use a jack to support the engine before the
upper bracket is removed.
. Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25 mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPERBRACKET
'17. Remove the cylinder head cover'
CYLINDERHEAD COVER
(cont'd)
6-29

Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, Dt6Y8 enginesl
NOTEr When reassembling the primary rocker arm,carefully apply air pressure to the oil passage of therocker arm.
1. Inspect the rocker arm piston. push it manually.- lf it does not move smoothly, replace the rockerarm assembty.
Dl6Y5 engine:
ROCKER ARM
TIMING PISTON
TIMING SPRING
SYNCHRONTZINGPISTON
SECONDARYROCKER ARM
MID ROCKER ARM
PRIMARY ROCKER
SYNCHRONIZINGPISTON A
NOTE:
. Apply oil to the pistons when reassembling.o Bundle the rocker arms with a rubber band to preventthem from separating.
6-34
(\
DI6YS engine:
NOTE: Set the timing plate and return spring as shownoerow.
RETURN
CAMSHAFT HOLDER
Dl6Yg engine:
2. Remove the lost motion assembly from the holderand inspect it. Test it by pushing the plunger withyour finger.- lf the lost motion assembly plunger does notmove smoothly, replace it.
LOST MOTION ASSEMBLY
\a
Pu3h
I

Valve Guides
7.
VALVESEAT
PFUSSIAN BTUE COMPOUNO
The actual valve seating surface. as shown by the
blue comDound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 60'cutter to
move it down, then one more cut with the 45'
cutter to restore seat width,
. lf it is too low (closer to the vslve edge), you
must make a second cut with the 30" cutter to
move it uD, then one more cut with the 45'cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45" cutter.
lnsert the intake and exhaust valves in the head and
measure the valve stem installed height.
Intake. Exhau3t Siem Installsd Height:
Standard (New): 53.17 - 53.6,4 mm
12.093 - 2.112 in)
Sorvice Limit: 53.89 mm (2.122 in)
lf the valve stem installed height is over the service
limit. reDlace the valve and recheck. lf its still over
the service limit, replace the cylinder head; the
valve seat in the head is too deep.
VALVE STEMINSTALLED HEIGHT
8.
\-
Replacement
1.As illustrated below, use a commercially-available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. In most cases.
the same procedure can be done using the special
tool and a conventional hammer.
VALVE GUIDE DRIVERlCommerciallv available)5.3 mm
87 mm +- 57 mft
t3.43 in) | 12 24 inl
tr-r'10.8 mm(0.42 inl
or
VALVE GUIDE DRIVER, 5.5 mm
07742 - 0010100
Select the proper replacement guides. and chill them
in the freezer section of a refrigerator for about an
nour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150'C). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F (150"C1;
excessive heat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
{cont'd)
6-41