1996 HONDA CIVIC Engine control

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

VTEC Control System
Troubleshooting Flowchart
tFtrsrl #ilH:::lj1t:"J:T,?ffnostic
rrouble code (Drc) Pr25e: A probrem in the vrEc Pressure switch circuit or
Reter to page 1 l-38 th roug h 1 1-55 before trou bleshooting.
* Road Test:Accelerate in 1st gear to an engine speed over 3,000 rpm(D16Y5 engine) or 6,000 rpm (D'16Y8 engine).Hold that engine speed for at least two seconds.It DTC P1259 is not repeated during the first road test, repeatthis test two more tames.
VTEC PRESSURE SWITCH 2PCONNECTOR
Terminal side ofmale terminals
Wire sid6 ol femalerermtnats
VTM
l1 (BLu/BLK)
f;-) |I
I
Y
I
The MIL has been reoorted on.DTC P1259 is sto.ed.
Check the VTEC Cont.ol Syst6m:1. Do the engine control module(ECM)/powertrain control module lPCM) Reset Procedure (see
section 11).2. Stan the engine.3. Warm up the engine to normaloperating temperature (cool-
ing fan comes on).4. Do the Boad Test.*Intermittont tailura, 3y3t.m is OKat thia time.Check for ooor connoctionr o.loose wirea at VTEC oiassurclwitch, VTEC solonoid valvo .ndECM/PCM,
ls OTC P1259 indicated?
Test rhe VTEC Prensure Switch:1. Turn the ignition switch OFF.2. Disconnect the VTEC Pressureswitch 2P connector.3. Check for continuity betweenVTEC pressure switch 2P con-nector terminal No. 1 and No.2.
Replace the VTEC preasure 3witch.ls there continuity?
Te3t the VTEC Pressure SwitchWire:1. Turn the ignition switch ON lll).2. Measure the voltage betweenVTEC press u re switch 2Pconnector No. l and bodyground.
In3poct for en opon or shod toground in thG wi.. bctwoon thoVTEC pro$ur6 switch rnd ECM/PCM l'96 - 9a: C15,'99 - 00: C101.lf tha wiro i3 OK,3ubrtitute aknown-good ECM/PCM andrecheck.
ls there battery voltage?
{To page 6'4i

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).
:(
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Cylinder Head
lllustrated Index (cont'dl
(-/) _.- E "or to reassembring, crean at the parts in sorvent, dry them and appry rubricant to anv contact oarts.
D16Y7 engine:
ROCK€R ARMASSEMBLYRemoval, page 6 30Inspection, page 6-35
8 x 1.25 mm20 N.m (2.0 kgt.m, 14 tbt.ftlApply engine oil to the
H
B
O-RINGReplace.
INTAKE VALVE SEALReplace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
:a
ti
VALVE
SPRING RETAINER
EXHAUST VALVESEAL
VALVE SPRINGSEAT
EXHAUST VALVEGUIDErnspectron, page 6,39Beplacement, page 6 4lAeaming, page 6-43
8 x 1.25 mm37 N m (3.8 kgt m,27 tbtftlApply engine oiltothe threads.
INTAKE VALVERemoval, page 6-38lnstallation, page 6-43
Removal, page 6,27Warpage, page 6 40Valve seat reconditioning,page 6-40Installation, page 6-45
VALVE
t
t
t
CAMSHAFTnspectron, page 6-36
OIL CONTROLORIFICEClean.
KEEPERS
\
EXHAUST VALSPRING
c -A9-2.+
L
6x1.0mm12 N.m (1.2 kst.m, 8.7 tbf.ft)Apply engine oit to thethreads.
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVESPRING

D16Y5 engine:
I x 1.25 mm20 N.m (2,0 kgf m, 14 lbf ft)
Apply engine oilto the
threads.ROCKEB ARMASSEMBLYFemoval, page 6-30
Inspection, Page 6-34
6x1.0mm12 N.m 11.2 kgf m, 8.7 lbf'ftl
Apply engine oilto the
threads.
VALVE KCEPERS
SPRING RETAINER
CAMSHAFTInspection, page 6-36
6x1.0mm12 N,m 11.28.7 tbf.ft)
WEC SOLENOIDVALVEBINTAKE VALVESPRING
INTAKE VALVE SEAL
Replace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
CAMSHAFTPUL|'IY
VTEC SOLENOIDVALVE FILTERReplace.
OIL CONTROLORIFICEClean.
VALVE
SPRING RETAINEB
EXHAUST V
SPRING
VE
EXHAUST VALVE
SEALt"o'""".uoau,
SEATReplace.
GUIDEInspection, page 6-39Replacement, Page 6-41
Reaming, page 6-43EXHAUSTVALVEOIL SEALReplace.
HEAD
8 x 1.25 mm
37 N.m 13.8 kgf.m,
27 tbf.frlApply engine oiltothe lhreads.
(cont'd)
6-25
INTAKE VALVERemoval, page 6 38
Installalion, Page 6 43Removal, page 6-27Warpage, Page 6 40
Valve seat reconditioning'page 6-40lnstallation, page 6_45

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,

Cylinder Head
Removal (cont'd)
9. Relieve fuel pressure (see section 11),
E@E Do not smoke while working on tho fuelsystem. Ke6p opgn flame or gpark away from lhework area, Drain fuel only into an app.oved containgr.
10. Remove the evaporative emission (EVAP) controlcanister hose, fuel feed hose and breather hose.
D16Y7 engine:
BANJO BOLT33 N.m {3.4 kgt m,25 tbf.ftt
BREATHER HOSE
D15Y5, Dl6YB engines:
BANJO AOLT33 N.m (3.4 kgf.rn,25 tbf.ftt
EVAP CONTROLCANISTER HOSE
6-28
(
1 1. Remove the brake booster vacuum hose. fuel returnhose and vacuum hose (see page S_4).
12. Remove the water bypass hose and positive crank_case ventilation (pCV) hose.
016V7 engine:
PCV HOSE
D16Y5, D16Y8 engines:
\a
I
WATER EYPASS
PCV HOSE

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