engine oil HONDA CIVIC 2000 6.G Repair Manual

lllustrated Index
(cont'd)
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft(see page 7,11).identification markings
Lubricate all internal parts with engine oil duringreassembtv.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTON RINGSReplacement. page 7-20Measurement, pages 7 20 andj-21Alignment, page 7-21
PISTON PINRemoval, page 7,17Installation, page 7-18Inspection, page 7,19
CONNECTING RODEnd play, page 7-8Selection, page 7,18
CONNECTING RODBEARINGSClearance, page 7 11Selection, page 7-11
CONNECTING ROD BEARING CAPInstallation, page 7-23NOTE: lnstall caps so thebearing recess is on thesame side as the recessin the rod.
PISTONInspectron, page 7-15NOTE: Betore removing the piston, inspect thetop of the cylinder bore for carbon build-up orridge. Bemove ridge if necessary, page 7-13
ENGINE BLOCKCylinder bore inspection, page 7-16Warpage inspection, page 7,'16Cylinder bore honing, page 7,17
Inspect top of each cylinder borefor carbon build-up or ridgebefore removing piston.Remove ridge if necessary, page 7-13
CONNECTING ROD CAP NUT816A2 €ngin6:9 x 0.75 mm{0 N.m (4.1 kgt m, 30 tbf.ftlD16Y5, Dl6Y7. D16Y8 engines:8 x 0.75 mm3l N.m {3.2 kg{.m,23 tbt.fr)Apply engine oiltothe bolt threads.NOTE: After torquing each bearingcap, rotate crankshaft tocheck for binding.
7-6

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.

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)

Pistons and Crankshaft
Removal
1. Remove the oil pan assembly.
2. Remove the right side cover.
816A2 engine
D16Y5, Dl6Y7, D16Y8 ongines
RIGHT SIDE
7-12
\
3. Remove the oil screen.
4. R€move the oil pump.
816A2 engin€
OIL SCREEN
D16Y5, D1oyr, D16Y8 engin.s
O-RINGReplace.
5, Remove the baffle plate (816A2 engine).
OIL PUMP

Crankshaft
Inspection
. Clean the crankshaft oil passages with pipe cleaners
or a suitable brush.
. Check the keyway and threads.
Alignment
. Measure runout on all main journals to make
sure the crank is not bent.
. The difference between measurements on eachjournal must not be more than the service limit.
Crankshaft Total Indicated Runout:
Bl6A2 engine:
Standard (Newl: 0.020 mm {0.0008 in} max.
Service Limit: 0.030 mm {0.0012 inl
D16Y5, D15Y7, D15Y8 engines:
Standsrd {New): 0.03 mm (0.001 in} max.
Service Limit; 0.0i1 mm 10.002 in)
Support with lathetype tool or V blocks.
7-14
Out-of-Round and Tapet
. Measure out-of-round at the middle of each rod
and main journal in two places.
a The difference between measurements on eachjournal must not be more than the service limit.
Joulnal Out-of-Round:
81642 engine:
Standard (New): 0.0004 mm {0.0002 in) max.
Service Limit: 0.006 mm {0.0002 in)
Dr6Y5, Dl6Y7, D16Y8 engines:
Standard (Newl: 0.0025 mm (0.0001 inl max.
Service Limh: 0.005 mm (0.0002 inl
round at middle.
. Measure taper at the edges of each rod and mainjournal.
. The difference between measurements on eachjournal must not be more than the service limit.
JournalTaDer:
B16A2 ongine:
Standard lNewl: 0.005 mm (0.0002 inl max.
Service Limit: 0.010 mm (0.00i1 inl
D16Y5, D16Y7, Dl6YB engines:
Standard (New): 0.0025 mm {0.0001 in) max.
Service Limit: 0.005 mm (0.0002 in)
\

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

Connecting RodsPiston Pins
Selection
Each rod falls into one of four tolerance ranges {from O to+ 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)increments) depending on the size of its big end bore. lt,sthen stamped with a number {1, 2,3, or 4) indicating therange.
You may find any combination ot l, 2, 3, or 4 in any
engrne.
Normal Eore Size: 48.0 mm (1.89 in)
NOTE:
o Reference numbers are for big end bore size and doNOT indicate the position of the rod in the engine.. Inspect connecting rod for cracks and heat damage.
CONNECTING ROD AOREREFERENCE NUMBERHalf of number is stamped onbearing cap, the other half onconnectrng rod.
7-18
Installation
1. Use a hydraulic press for installation.
. When pressing the pin in or out, be sure you posi
tion the recessed flat on the piston against the lugson the base attachment.
816A2 engine
The arrow must face thetiming belt side of theeng Ine.
The mark must facethe timing belt sideof the engine.
D16Y5, D16Y7, O16Y8 engines
The arrow must face thetiming belt side o{ theengine and the connectingrod oil hole must face therear of the engine.
Adjust the length of thepiston pin driver to53 mm (2.09 4n)
PISTON PIN DRIVER SHAFT07973-PEOo3r0
PISTON PIN DRIVER HEAD
il--Z
P,"roNPrN
PILOT COLLAR07973-PE00200
PISTON PIN BASE INSERT07973 PEO0400
PISTON EASE HEAO07973 -5800100
,(
a

Piston Rings
End Gap
1.Using a piston, push a new ring into the cylinderbore 15 - 20 mm (0.6 - 0.8 in) from the bottom.
Measure the piston ring end-gap with a feeler gauge:
. lf the gap is too small, check to see if you have
the proper rings for your engine.. lf the gap is too large. recheck the cylinder borediameter against the wear limits on page 7-16,
lf the bore is over the service limit, the cvlinderblock must be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd (New): 0.20 - 0.35 mm
{0.008 - 0.01,1 in)
Service Limit: 0.60 mm l0-02i1 inl
D16Y5. Dl6Y7, D16Y8 enginos
Standard lNewl: 0.15 - 0.30 mm
{0.006 - 0.012 in)
Ssrvic€ Limit 0.60 mm {0.024 inl
Socond Ring
816A2 ongina
Standard (Nowl: 0.40 - 0.55 mm
10.016 - 0.022 inl
Service Limit: 0.70 mm (0.028 inl
D16Y5, D16Y7, Dt6Y8 engines
Standard (New): 0.30 - 0.ia5 mm
{0.012 - 0.018 in)
Sorvice Limit 0.70 mm 10.028 inl
Oil Ring
81642 ongine
Standard {Now): 0.20 - 0.50 mm(0.008 - 0.020 inl
Sorvico Limit: 0.70 mm (0.028 in)
Dl6Y5. Dl6Y7, D16Y8 €nginos
Standard (Nowli 0.20 - 0.70 mm(0.008 - 0.028 inl
Servica Limit: 0.80 mm 10.031 in)
7-20
Replacement
1.Using a ring expander. remove the old piston rings.
Clean all ring grooves thoroughly.
NOTE:
. Use a squared-off broken ring or ring groove
cleaner with blade to fit piston grooves.
o Top ring groove is 1.0 mm (0.039 in)wide.. Second ring groove is 1.2 mm (0.047 in) wide.. Oil ring groove is 2,8 mm (0.11 in) wide.. File down the blade if necessary.
CAUTION: Do noi use a wire blush to clean ringlands. or cut ring lands deepol with cleaning tool.
NOTE: lfthe piston is to be separated from the con-necting rod, do not install new rings yet.
3. Install new rings in the proper sequence and posi-
taon (see page 7-22).
NOTE: Do not reuse old piston rings.
(Commercially available)

PistonsGrankshaft
lnstallation
Before installing the pistons, apply a coat of
engine oil to the ring grooves and cylinder
bores.
lf the crankshaft is already installed:
. Set the crankshaft to BDC for each cylinder.
. Remove the connecting rod caps, and slip short
sections of rubber hose over the threaded ends
of the connecting rod bolts.
. lnstall the ring compressor. check that the bear-
ing is securely in place, then position the piston
in the cylinder, and tap it in using the wooden
handle of a hammer.
o Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal align-
ment before pushing the piston into place
. Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torque the nuts to:
815A2 engine:
40 N.m {,1.1 kgf.m, 30 lbf'ft|
D16Y5, D16Y7, D16Y8 engines:
31 N.m (3.2 kgf'm,23 lbf'ft)
lf the crankshaft is not installed:
. Remove the rod caps and bearings, install the ring
compressor, then position the piston in the cylin-
der, and tap it in using the wooden handle of a
hammer.
. Position all Distons at top dead center.
1.
2.
The arrcw must facethe taming belt sideof the engine.
CONNECTING ROOOIL HOLE lD16Y5, D16Y7, D16YB ongines)
NOTE: Maintain downward force on the ring com-
pressor to prevent the rings from expanding before
entering the cylinder bore.
RUBBER
,lll
lnstallation
Before installing the crankshaft, apply a coat of
engine oil to the main bearings and rod bearings.
Insert the bearing halves into the cylinder block and
connecting rods.
Hold the crankshaft so the rod journals for cylinders
No.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rod
journals into connecting rods No. 2 and No. 3, and
install the rod caps and nuts finger-tight.
1.
2.
3.
5.
Grooved sides faceoulward.Botate the crankshaft clockwise, seat journals into
connecting rods No, 1 and No.4, and install the rod
caps and nuts finger-tight.
NOTE: Install caps so the bearing recess is on the
same side as the recess in the rod.
Check rod bearing clearance with plastigage (see
page 7-11), then torque the capnuts. Apply engine
oil to the bolt threads.
Torque:
816A2 sngine:/l{, N.m {a.l kgf.m, 30 lbf'ftl
D16Y5, D16Y7, Dl6Y8 engines:
31 N.m (3.2 kgf.m, 23 lbf'ft|
NOTE: Reference numbers on connecting rod are
for big-end bore tolerance and do not indicate the
position of piston in the engine.
Line up the marks wheninstalling the connectrng rod
cap.
6. Install the thrust washers on the No. 4 journal. Oil(cont'd)
7-23
the thrust washer surfaces,

Crankshaft
Installation (cont'd)
7. Installthe main bearing caps.
Check clearance with plastigage (see page 7-9), thentighten the bearing cap bolts in 2 steps.
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft)
Second stop:
B1642 engine:
76 N.m {7.8 kgf.m, 56 lbf.ft)
D16Y5, D16Y7, D16Y8 engines:
51 N.m (5.2 kgf.m, 38 lbf.ft)
NOTE: Coat the thrust washer surfaces and boltthreads with oil.
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
oocoo
CAUTION: Whenever any crankshaft or connectingrod bearing is replaced, it is necGssary after reassom-bly to run the engine at idling spe6d until it reachesnormal operating temperature, than continue to runit for approximately 15 minutos.
:V fr\-/.---\-/.-
7-24
NOTE:
. Use liquid gasket, part No. 08718 - 0001 or08718-0003.
. Check that the mating surfaces are clean and drybefore apptying liquid gasket.
. Apply liquid gasket evenly, being careful to coverall the mating surface.. To prevent oil leakage, apply liquid gasket to theinner threads of the bolt holes.. Do not install the parts if five minutes or morehave elapsed since applying the liquid gasket.
Instead reapply liquid gasket after removing theold residue.
. After assembly, wait at least 30 minutes beforefilling the engine with oil.
L Apply liquid gasket to the block mating surface ofthe right side cover, then install it on the cylinderblock.
Bl6A2 engine;
Apply tiquid gaslet alongthe broken line.
D16Y5, D16Y7, D16Y8 engines:
RIGHT SIDE COVER