1996 HONDA CIVIC D16y8 vtec

Design Specifications
ITEMMETRICENGLISHNOTEDII/IENSIONS Overall Length2 door Coupe/4 door Sedan (,96 98)('99,'00)2 door Hatchback (,96, ,97)
('98 - 00)OverallwidthOverall height 2 door Coupe/2 door Hatchback4-door SedanWheelbase
I Track FronvRearGround ClearanceSeatiog Capacity
4,445 mm4,450 mm4,170 mm4,180 mm1,705 mm1,375 mm1,390 mm2,620 mm1,475/1,415 mm150 mm
175.0 in115.2 in164.2 in164.6 in67.1 in54.1 in54.7 in103.1 in58.1/58.15.9 in
WEIGHT (USA)Gross Vehicle Weight Raring (GVWR)2 door Coupe HX M/T, DX M/THX CVI ('96)HX CVT ('97,'98)HX CVT ('99}DX A,/T (96 98,DX A"/T ('99, '00)
EXSi2 door Hatchbacl CX. DX r'96, 97,cx, DX ('98)cx (,99, ,00)
DXM/Ti'99,00iDX A/T ( 99, 00,4 door Sedan DX, LX, DX-VEX
3,290 tbs3,320 tbs3,330 tbs3,360 rbs3,290 rbs3,310 tbs3,440 tbs3,480 tbs3,285 tbs3,290 tbs3,290 tbs3,290 tbs3,330lbs3,330 tbs3,460 tbsWEIGHT (CANADA)Gross Vehicle Weight Bating (GVWR)2-door Coupe DX ('96)DX ('97 00)DX-Gsi 1,96)si ('97 - 00)siR2 door Hatchback CX, CX,G ('96)cx, cx,G 1,97)cx-G (,98)
cx ('98 00)DX M/T, SE M/IDX A,/T, SE A,/T4 door Sedan LX, LX VEX M/IEX A/T
1,500 ks1,510 kg1,510 kg1,560 kg1,570 kg1,590 ks1,495 kg1,505 kg1,510 ks1,510 ks1,510 kg1,530 kg1,510 kg1,510 ks1,540 ksENGINEType
Cylinder ArrangementBore and Stroke D16Y5, D16Y7, Dt6y8B 1642DisplacementD16Y5, D16Y7, Dl6Y881642Compression Ratio D16Y5, D16y7D16Y8816A2Valve TrainLubrication SystemOil Pump Displacement at 6,800 engine rprnD16Y5, D,l6Y7, D16Y881642Water Pump Displacementat 6,000 engine rpm 016Y5, D16Y7, D16y8816A2Fuel Required D16Y5, D16Y7, D16y8
816A2
Water-cooled, 4-stroke SOHC*1, SOHCVTEC"', SOHC WEC.E'3, DOHC VTEC{gasoline engineInline 4 cylinder, transverse2.95 x 3.54 in3.19 x 3.05 in97.0 cu-in97.3 cu in9.49.610.2Belt driven, 4 valve per cylinderForced and wet sump, trochoid pump
33.4 f (35.3 US qt, 29.4 lmp qt)/minute43.8 | (46.3 US qt, 38.6 lmp qt)/minute
125 { {132 US qt, 110 lmp qt}/minute140 f {148 US qt, 123 lmp qt}/minuteUNLEADED gasoline with 86 PumpOctane Number or higherPremium UNLEADED gasoline 91 PumpOctane Number or higher
75.0 x 90.0 mm81.0 x 77.4 mm1,590 cm31,595 cm3
*1: D16Y7*': D16Y8*3: D16Y5*': 816A2
STARTEBType/MakeNormal OutputNominalVohageHour RatingDirection of Rotation
Gear reduction/MITSUBA1.0 kw, 1.2 kw12V30 secondsClockwise as viewed from gear end
5-Z.V
-

Cylinder Head/Valve Train
Dl6Y5, D16Y7, Dl6Y8 engines
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection ............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5 engine) ............................. 6-7
Manual Inspection
(D16Yg enginel ................'............ 6-7
Inspection Using Special Tools
{D16Y5 engine} .....................""'... 6-8
Inspection Using Special Tools
(D16Y8 engine) .........................'.'. 6-10
Valve Clearance
Adiustment ..."".....6-12
Valve Seals
Replacement (Cylinder head removal
not requiredl ................................ 6-1tl
Crankshaft Pulley and PulleY Bolt
Replacement ."...... &16
Timing Selt
lllustrated Index ............................... 6-17
Inspection .............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal ......,,......... 6-19
lnstallation ............. 6-20
Crankshaft Speed Fluctuation (CKF) Sensor
Repf acement .........6'22
Cylinder Head
lllustrated Index ............................... 6-23
Removal ................. 6-27
Warpage ................ 6-40
lnstallation ............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly ............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, D16Yg
enginesl "..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection .............. 6-36
Valves, Valve Springs and Valve Seals
Removal ........""..... 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement .........6-41
Reaming .......'......'.' 6-43
Valve Seats
Reconditioning .'....6'40
Valves
lnstallation ............. 6-tt3
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
lnstallation ............. 6-44

I
VTEC Control System
Troubleshooting Flowchart (cont'd)
VTEC PRESSURE SwlTCH 2PCONNECTOR
Wire side of female(€rmrnats
VTEC SOLENOID VALVE lPCONNECTOR
I r----'t I
ll ' ff---r'-'1
I
I
-L
Terminal side ofmale terminal
A/T LOW PRESSUREw/PAt{EL07406-0070300
NOTE: Keep measuring time as short aspossible because engine is running with noload (less than one minute).
PRESSURE GAUGEADAPTER07NAJ - P07010A
A/T PRESSURE I{OSE07406 - 0020201
ot
A/T PRESSURE HOSE.2,210 mm07MAJ - PY&llA andA/T PRESSURE ADAPTER07MAJ - PY,()120
6-4
(From page 6-3)
(To page 6-5)
Test the VTEC Pr6suro SwitchWiro:Nleasure voltage across the VTECpressure switch 2P connector.
. Rcpai. opon in tho wirebrtw.en VTEC pr6.urc switchand G101.. lf th. wir6 b OK, sub.thuto alnown-good ECM/PCM !ndracheck.
ls there baftery voltage?
Te3t the VTEC Solonoid V.lve:1. Turn the ignition switch OFF.2. Disconnect the VTEC solenoidvalve 1P connector.3. Check for continuity betweenthe VTEC solenoid valve 1Pconnector terminal No. 1 andbody ground.
ls there 14 - 30 0?
Te3t tho WEC Solonoid Vatvo:'1. Remove the VTEC pressureswatch and install the specialtool as shown, then reinstallthe VTEC pressure switch.2. Reconnoct the VTEC solenoidvalve 1P connector and VTECpressure switch 2P connector.3, Connect the tachometer (seesection 11).4. Stan the engine.5, Warm up engine to normaloperating temperature (cool,ing fan comes on).6. Check oil pressure at enginespeeds D16Y5 engine: 1,000and 3.000 rpm, D16Y8 engine:1,000,3,000 and 5,000 rpm.
ls pressure below 49 kPa(0.5 kgflcm,, 7 psi)?In.poct the VTEC aolonoid vllvols.c p.g. &6).
:(
t
I
t
:
t
I
I

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,

Cylinder Head
lllustrated Index (cont'dl
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVE
VTEC SOLENOIDVALVE FILTEBReplace.
OIL CONTROLORIFICEClean.
INTAKE VALVE SEALReplace.VALVE SPRINGSEAT
INTAKE VAI.VEGUIOE
CAMSHAFTPULLEY
I
I
VALVE KEEPERS
SPRING RET
EXHAUST VALVESPRING
@
EXHAUST VALVESEALReplace.
8 x 1.25 mm37 N.m 13.8 kgt m,27 tbfitlApply engine oiltothe threads.
EXHAUSTVALVE
-vp
e,.io"o reassembring, crean at the parts in sorvent, dry them and appry rubricant to any contact parts.
D16Y8 engine:
LOST MOTIONASSEMgLY
ROCKER ARMASSEMBLYRemoval, page 6 30Inspection, page 6-34
5xl.0mm12 N.m {1.28.7 tbf.ft)
VALVE SPRINGSEATEXHAUSTVALVE O.RINGGUIDE Replace.Inspection, page 6 39Replacement, page 6 41Reaming, page 6 43
LOST MOTIONASSEMBLYHOLDER
INTAKE VALVEBemoval, page 6 38Installation, page 6 43
20 N.m 12.0 kgl.m, 14 tbf.ft)Apply engine oit to thethreads.
\
\
s9illl
CAMSHAFTInspection, page 6-36
OIL SEALBeplace.
CYLINDER HEADRemoval, page 6 27Warpage, page 6-40Valve seat reconditioning,page 6 40Installation, page 6-45
6x1.0mm12 N.m (1.2 kgt.m,8.7 lbf.ftlApply engine oil to thethreads,

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

Troubleshooting
E n gine/P_o,weft ra in Control Module Term inal Arra n gement('96 - 98 Models, '99 - 00 Dl6yS engine with M/T)
-
ECM/PCM CONNECTOR A I32PI
1INJ62INJ3INJ21
INJl567I
LG110PGll1
IGPl12
ACV
131115
PCS
16
FLR17acc18MIL19ALTC20
tcM22PG221IGP2272A25
VSV30
SLU
ECM/PCM CONNECTOR A (32P)
'2: A./T (D16Y7, 016Y8 engine)13: CvT (D16Y5 enoin€)',4: A/T and D16y7 engine*5: Except A/T and D16Y7 €nsine'6r A/T (D16Y8 ensine)'7 Cw 1D16Y5 eng,nel and D16y8 ensrne'"'3:Bi..I?'Jt;".'e'.!ti.?i?l'""."T8"_";btfr
"fl
1-88
Wire side of female terminals
NOTE:Standard battery voltage12ts
'10i i,4/T (D16V5 engine)r11 Ex.ept M/l (D16V5 enqinelr12: 016Y5, D16YB enqine
r15:'97 016Y7 engine lcoupe: KL modet, sedan: KL (LXl modet),'98 D16Y7 engine
1
1
Sign.l
YELlNJ4 (No.4 FUEL INJECIOB)D ves No 4 ruel injector.Wilh engine runninq: ddly coniroted2BLUlNJ3 lNo. 3 FUEL TNJECTOBJDrives No. 3 lue Inteclor.38EDINJ2 (NO, 2 FUEI INJECTON)Drives No. 2 iuel njector.88NlNJl (No. 1 FUEL INJECTOB)Dives No. 1 ruelinjector.
5SO2SIITC (SECONDAFY HEATEDOXYGEN SENSOF HEATEF CONTFOL)
Orives secondary heated oxyqen sensorWith ignilion switch ON (lll: batery vo lageWith f!llywarmed up engine runninq:dLtv controled
6BLXAVHTPO2SHTC (PRIMAFY HEATEOOXYGEN SENSOR HEATERCONTROL)
Drives prihary healed oxygen sensorWith ignition switch ON ltt):baneryvottasewlhrdllywdrmedupcngne,Lnnrrq dury,orl.otred
FED{ESOL (EGF CONTRO!SOIENOIO VALVE)Drives EGF conlrolsoleno d vatve.Wilh EGR operating during drving wiih fu|y warmedup engrne: duty controttedWilh EGF nol opefating:O VE.EGRWith EGF operating du.ing driv og wilh iuty warmedup en9ine: dutycont.olted.With EGR not ooeralino; o V8*r/GFN/YELWS (VTEC SOLENOTD VALVE)Drives VTEC solenoid va veWilh eng ne at ow engine speed:O VWirh engine at h gh enqine speedr banery vohaae9BflN/BLKLG1 (LOGIC GROUND)Gro!nd lorthe €CM/PCM conlrotc rcuit.Lesslhan 1.0 V at a ttimest0ALKPG1 IPOWEF GFOUND)Ground ior rhe ECM/PCM power.tcuf.11YEVBLKIGPT iPOWEF SOUFCE)Power source forthe Ec[,l/PcM conlroWilh ignition swirch ON (tt): battery voltageWith gntron switch OFF: 0 VBLVBLUIACV (IDLE AIN CONTROL VALVE)Wilh engine r!nn ng: dlty contro ed13,.o8NIACV N lIDLE AI8 CONTFOLVALVE NEGATIVE SIOE)Drivesthe IAC valve {negalive side).
BLVBLUIACV P (IDLE AI8 CQNTROLVALVE POSITIVE SIDE)Orives IAC vaive (posilive side).
FEO/YELPCS (EVAP PURGE CONTFOTSOIENOIOVALVE)Drives EVAP pu.ge controtsolenoid vatve.Wilh engioe running, engin€ cootani betow 154,F'68'Cr bancry vohaSe w'ln ens nc runn,.o. eng,rc
GRN/YELFL8 (FUEL PU[4P FELAY)Orives fuelpump relay.0 V {or two secor os ahe' tJ n ng 'onir or \wnch ON ,,,,,
I7BLI(REOACC (A,/C CLUTCH RELAY)Drives A/C clutch relay.Wirh compressor ONr0 VWilh compressof OFF:banery votrage18GFN/ONNMIL (I\,lALFUNCTION INDICATOFWith MIL lLrned ON: 0 VWith illl turned OFF: banery volaqe19',AITC {AITERNAIOR CONIROL)se.ds ahernator controt signat.Wirh fully warmed.up engine ru.ntng: battery votlas€During drivins wnh smatl eteclricat toad: O V
20YEVGRNICM (IGNI'TION CONTROLMOOU!E)with ignltlon swilch ON (tl):b6n€ry vohageWilh ensine runnins: aboul t0 V (depending on
22BRN/BLKLG2 (LOGIC GAOUND)Ground for the ECM,/PCM conrrot ci'cu LLess than 1.0 V at a tt mes23BLKPG2 iPOWEA GROUND)Gro!nd lor the ECM/PCM power circuir.24YEUBLKlGP2 (POW€R SOUSCE)Power sou.ce lor the ECM/PCl, conrrolWnh ignilion swilch ON {it):battery vohageWilh ignilion switch OFF:0 V25*6WHT/FEDVSEF IREFEfl ENCE VOLTAGE)Provrdes reference voIaOe to TCM.With ignition switch ON (tt):abour 5 VWth gnition swltch OFF: O V21'1GFNFANC {RAOIATOR FANCONTFOL)Drives radialof fan ielay.With radialor fan f!nn nqr O VWilh radiato.tan stopped: batteryBL!2WBS (EVAP BYPASSSOLENOIO VALVE]Orives EVAP bypass sotenotd va !e.With ignirion swrrch ON (tt):barery vo rase
LT GRNA/VHTVSV (EVAP CONTFOTCANISTEFVENT SHUT VAIVE)Drives EVAP conlfot canisrer venl shulwnh ignirion sw'tch ON lr|l barery volaqe
WHT/NEDSLU (INTEFLOCK CONTFOLUNIT)Detects intenock conlrotLn t signalWhh ignition switch ON (tt)and brake pedadepf essed: battery vollage

Troubleshooting
Engine/P_o_wgrtrain Control Module Terminal Arrangement('96 - 98 Models '99 - 00 Dt6y5 engine with M/T) tc'oniOi
ECM/PCM CONNECTOR C {31PI
1
CKFP
2
CXPPTDCPa
ACS
5
sTs
7
scsII
rMA
10
v8u121314t51517
ALTF
TE
vss23lP+
21252930
TMA
Wire side of female terminalsECM/PCM CONNECTOR C (31PI
NOTE: Standard baftery voltage is 12 V
'1: USA modelr2rA,.T (D16Y7, O16Y8 ensane)*3: CVT (O16Y5 engine)*4: Ay'T and O16Y7 engine'5: Excepl A./T snd Dl6Y7 engine16: Ay'T (D16Y8 ensine){7: CVT (Dl6Y5 eosine) and O16Y8 enoine"8: 96 Dl6Y8 engine (coupe),'97 D16y8 engine (coupe: atl:ed-9I t!!rnodelr,'98 D16y5 ensine,,98 D16y8 e;sine.D16Y5 lM/T) ensine
1-90
19: D16Y5 engine'10: M/T (Dl6Y5 engine)*11r Except M/T 116Y5 engine)*12: D16Y5, D16Y8 engine*13: Dl6Y8 enqine*14: O16Y7 enginei15: '-97 O16Y7 engjne (coupe: KL modet, sedan: KL (LX) modet),'98D16Y7 enqine'99 - 00
1
To.min!lnumberWiracoloaTorminalnameDo6criptlonSignal
1BLU/REDCKFP (CKF SENSOR P SIDE)Detects CKF sensor.With engine running: pulses2BLUCKPP (CKP SENSOF PSIDE)Detects CKP sensor.With engine running: pulses3GRNTDCP {TDC SENSOR PSIDE}Detects TDC sensor,With engine running: putses4YELCYPP (CYP SENSOR P SIDE)Detects CYP sensor.With engine running: pulses
5BLU/FEDACS {Tr'C SWITCH SIGNAL)Detects ,ay'C sw;tch signat.With Iy'C switch ONr 0 VWith Ay'C switch OFF: batrery vottage
6BLU/ORNSTS (STARTER SWITCHSIGNAL)Detects staner swilch signal,With staner switch ON ltlt): batery vohageWith staner switch OFF: 0 V
8RNSCS (SERVICE CHECKSIGNAL)Detects service check connector signal{the signalcausing a OTC indicationlWith the connector connected: O Vwith the connector disconnected: about 5 vor battery voltageLT 8LUK,LINE (DLC)Sends and receives scan iool signal,Wirh ignition switch ON { ): about 5 V
9+3GRYDat6 communication with TCM: ECMcontrol ctat6 outputWith ignition switch ON (tt):putses
10WHT/BLUVBU (VOLTAGE BACK UP)Power source forthe ECM/PCMcontrol circuit. Power sourc€ lortheDTC memory
Battery voltage at all times
11WHT/REDCKFM {CKF SENSOR MSIDE)Ground tor CKF sensor signal.
12CKPM (CKP SENSOR MSIDE)Ground for CKP sensor s;gnat.
REDTDCI\4 (TDC SENSOR MSIDE)Ground for TDC sensor signal.
14BLKCYPM (CKP SENSOB MSIDE}Groond for CYP sensor signal.
15."BLU/BLKVTM (VTEC PRESSUREswtTcH)Oetscts VTEC pressure switch signal.Wrth engine at low enginespeed:0 VWth engineathigh engine speed: tatteryvoltase
16GRN
PSPSW (P/S OIL PRESSUREswtTcH)Detects PSP switch signal.At idle with steering wheel in straight aheadposition:0 VAt idle with stsering wheet at fult tock batteryvoltage'17WHT/REDALTF (ALTERNATOR FRSIGNAL)Detects ahernator FR signal.With fullyw6rmed up engine running:0 V- bat-teryvohage (depending on electricat toad)18BLUI/VHTVSS {VEHICLE SPEED SEN-SOR}Oetects VSS signal.Whh ignitjon switch ON {tt) and front wheetsrotating: cycles 0 V- 5 V23+14BLKlP+ {HO2S PUtr4P CELL +}Controls HO2S pump ce .With ignition switch ON (ll): abour 0.5 - 5.3 V
24.10REDrP-, vs- {Ho2s coMt oN)Reference voltage supply.With fullywarmed up engine et idle:about2.6-2.8 V25*roVS+ (VS CELL VOLTAGE)Detects VS cell voltage.With ignition switch ON t): abour 7 V
29LT GRN*'ATPNP (Ar'T GEAR POSI,TroN swrTcH)Deteds Ay'T g6srposhion switch signat.In E orE position: O Vln any other position: battery vottage
RED{roCLSW (CLUTCH SWITCH}Detects clutch switch signal,Wilh clutch pedal released: about 5 VWith clutch pedal deDressed: O V30PNK4TMBData communication with TCM:ECM controldata inputWith ignit;on switch ON (lt):putses