1996 HONDA CIVIC Measurements

Unit of length: mm lin)
STANDARD {NEW) SERVICE LIMITMEASUREMENT
Differential
Dtri"*"t"|p'.b"gear
S"t rrg-t" b""il"s
Pinion shaft contact area LD.
Carrier-to pinion clearanceDrive shaft contact area l.D.Carrier to driveshaft clearance
BacklashLD.Pinion gear to-pinion shafl clearance
)uter race clearance
18.010 18.028'0.7091 - 0.7098)
0.023 0.057 (0.0009 - 0.0022) 0.1 (0 004)
26.025 - 26.045 (.0246 1 0254\0.045 0.086 (0.0018 - 0.0034) 0.12(0.005)
0 05 - 0.15 i0 002 0.006)18 042 18.066 {0.7103 0.7" l3)
0.055 - 0.095 (0.0022 - 0.0037) 0.15 {0.006)
0 0.15 (0 - 0.006) Adjlrst
MEASUBEMENT Wire DiaO.D. Free Length I No. of Coils
SpringsPH regulator valve spring 1 2 (0 047)
PH control valve spring 1 7 {0.067)PL regulator valve spring 0 9 (0.035)
PH'PL control valve spring 1 0 (0 039)
crutlh reduc'ns vdrve spnns ] :19 9]:lLLbrication valve spring I b (u ubJr
Shitt valve spring 1 4 (0.055)
Shift control valve spring 1 0 (0.039)
Stan clutch control valve spring 0.4 (0 016)
Pitot regulator valve spring 0.6 (0 024)
Start clutch valve accumulator spring 1 2 \0 O47)
Reverse control valve spring 1 2 (0.047)
Shift inhibitor valve spring 1 3 (0 051)
9.0 {0.354)13.4 (0.528)
1.2lO.2A3\10.0 (0.394)
16.8 (0.661)
13.4 (0.528)
8.2 (0.323)
1 .4 t0.29114.1 (0.161)
5.7 t0.224)8.3 {0.327)9.4 (0.370)
13.2 (0.520)
26.7 (1.051)
39.4 (1.551)
14.6 (0.575)
31.4 (1.236)
44.4 \1.14al51.6 (2.031)
34.1 (1.343)
19.3 (0.760)
12.1 (0.476)
9.5 (0.374)
29.8 (1.173)
31.4 (1.236)
48.3 (1.902)
r0.08.11.28.68.0
13.01.56.85.012.311.010.6
Section 14
SteeringSection 17
M/S: [,4anual steering, P/Sl Power steering*: When using a ne; bett, adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
Readjust the deflection or tension to used belt values.
cw
MEASUREMENTSTANDARD {NEWI
Steering wheelPlay at steering wheel circumferenceStarting load at steering wheelcircumferenceN (ksf, lbf)Manual steeringPower steering Engine running
0 - 10 (0 0.4)
15 (1.5,3.3)
29 (3.0,6.6)
GearboxAngle of rack guide screw loosened M/S
from locked position P/S
Preload at pinion gear shaft N m (kglcm, lbfin) M/S
20!5"20'Max0.5 - 1.7 (5 - 17,4.3 - 14.8i
0.6 1.2 (6 - 12, 5.20 - 10.42)
Pump pressure with valve closed(oil temp./speed: 40'C (105"F) min./idleDo not run for more than 5 seconds).kPa (kgtcm?, psi)
6,400 - 7,400 {65 - 75, 920 - 1,070)
Power steeringfluidRecommended power steering fluid
Fluid capacity | {US qt, lmp q0Reservoir
HONDA Power Steering Fluid
0.85 (0.90,0.75) at disassembly0.4 {0.42.0.35}
7.5 11.0 {0.30 - 0.43)with used belt
5.0 7.0 (0.20 0.28) with new belt10.5 - 14.0 10.41 - 0.55) with used belt7.5 10.010.30 0.39) with new belt
390 540 {40 55,88 '120) wrth used bek
340 - 490 (35 - 50, 77 - 110) with used belt
740 880 (75 - 90, 170 - 200) with new belt
640 780 (65 - 80, 143-176)with newbelt
Power steeringbelt*
Deflection with 98 N (10 kgf,22 lbf)
between pulleys '99 modell 81642 Engine Type only
'96 '99 models: Other Engine TYPes
ron.ionffiN (kgf, lbf) '99 model: 81642 Engine Tvpe only'96 -'99 models: Other Engine TYPes'99 modelr 81642 Engine TYPe onlY'96 '99 models: Other Engine TYPes
3-17

MEASUREMENTSTANOARO INEW}SERVICE LIMIT
algnmenlCamber FrontRearCaster FrontTotaltoe FrontBearFront wheel turning angle Inward wheelOutward wheel
0"00'1 1"-1.1 1'1'40' I 1"In'1.01 2.0 {1/16 t 1/'16)In 2.0 ljB (1/161 1/16)39.50'33'10'(Reference)
Bim runout Aluminum wheel AxialBadialSteelwheel AxialRadla I
0 0.7 (0 - 0.03)0- 0.7 (0 - 0.03)0 - 1.0 (0 0.04)0 - 1.0 (0 0.04)
2.0 (0.08)
1.5 10.06)2.0 {0.0B)1.5 (0.06)Wheel bearingEnd play FrontRear0 0.0s (0 - 0.002)0 0.05 (0 0.002)
Standards and Service Limits
Suspension - Section 18
Brakes - Section 19
*1. 5410 Stamped on the caliper body.*2. 2056 Stamped on the caliper body.
Air Conditioning - Section 22
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it of{.Readjust deflection or tension to used belt values.
3-18
MEASUREMENTSTANDARO INEWISERVICE LIMIT
Parklng brakePlay in stroke at 196 N (20 kgf, 44 lbfi lever forceTo be locked when pulled6 - I notchesFoot brakepeoalPedal height (with floor mat removed) M/TA/'T, CVTFree play
156.5 {6.16)161 (6 5/16)1 5(1/16-3/16)
Master cvlinderPiston to pushrod clearance0 - 0.4 (0 0.02)
Disc brakeDisc thickness FrontRearDisc runout FrontRearDisc parallelism Front and rearPad thackness Front
Rear
20.9 - 21.8 (0.82 - 0.86)8.9 - 9.1 (0.350 - 0.358)
9.5 10.5*'8.5 - 9.5*'7.0 8.0 (0.28-0.3r)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)
1.6 (0.06)1.6 (0.06)'r.6 (0.06)
Rear brakedrumLD.Lining thickness200 17.a7l4.0 (0.16)201 \7 .9112.0 {0.08}
MEASUREMENTSTANDARD INEWI
Conditioning
SANDEN
Lubricant type: SP 10 (P/N 38897 - Pl3 - A01AH or 3889Lubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
I - P13 A0li lFor refrigerant: HFC-134a (R,134a))
| 20 \2t3 0.11
I 45 (1 2/3, 1.6)10 (1/3,0.4)
10 t1/3,0.4)NIPPONDENSOLubricant type: ND'O|L8 (P/N 38899 - PR7 - 003) (For ReLubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
f.igerant: HFC,134a (R-134a))25 (s/6 0.9)60 (2,2.11
10 (1/3,0.4)
10 (1/3.0.4)
CompressorSANDENLubricant type: SP-10Lubricant capacity ml lfl oz, lmp oz)Field coil resistance at 68'F (20"C) OPulley-to-pressure plate clearance
130 150 (4 1/3 4.6, 5.0 - 5.3)
0.5 r 0.15 10.020 t 0.006)
NIPPONDENSOLubricant type: ND-OlL8 {P/N 38899 - PR7 ,003 or P/N 38899 pR7 - AO1) (For Refrigerant: HFC 134a {R,134a))Lubricant capacity m{(fl oz, lrnpoz) | 14O(4.7,4.9J -15S{5.2.5.4)Stator coil resistance at 20'C (68.F) 0Pulley-to-pressure plate clearance3.4 - 3.80.510.15 (0.0210.006)
Compressorbelt*Deffection with 98 N (1Okgl.22lbllbetween pulleys7.5 - 9.5 (0.30 0.37) with used belt5.0 - 6.5 (0.20 - 0.26)with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge340 490 i35 50, 77 - 110) with used bell690 - 830 (70 - 85, 150 190) with new belt

ElectricalSection 23
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off
Readiust deflection or tension to used belt values
Unit of englh: mm {n)
MEASUREMENTSTANDARD {NEW}
lgnition coilRated voltage VPrimary winding resistance at 68'F (20'C) oHITACHITEC
Secondary winding resastance at 68'F 120"C) kOHITACHITEC
12
0.45 0.550.63 0.11
22.4 - 33.612.A - 19.2
lgnition wireResistance at 68'F (20'C) kf)
Firing order
25 max.1-3-4 2
Spark plugTypeGap
See section 231.1 3, (o.o€ -3*.)
lgnition timingAt idle' BTDC lRed)
Alternator belt+Deflection with 98 N (10 kgf,22lbf)between pulleys8.0 - 10.5 {0.31 - 0.41} with used belt
6.0 - 8.5 {0.26- 0.33)with new belt
Belt tension N (kgf, lbf)
Measured with belt tension gauge340 - 490 (35 - 50, 77 110) with used belt
540 - 740 (55 - 75, 121. 165)whh newbert
(MITSUBISHI)Output l3.5 V at hot ACoal resistance (rotor) at 68'F (20"C) kO
Slip rins O.D.Brush lengthBrush spring tension g (oz)
STANDARD INEWI SERVICE LIMIT
753.4-3.8 I -
Z2.j \0.A9) 22.2 \0.47)19.0 (0.75) 5.0 (0.20)
340 420 (12.0 14.8)
Alternator(DENSOiOutput '13.5 V at hot A
Coil resistance (rotor) at 68'F (20'C) k0
Slip ring O.D.Erush lengthBrush spring tension g (oz)
802.2 - 3.014.4 (0.57) | 14.0 (0.55)
10.5 (0.41) 1.5 (0.06)
330 {11.6)
Starter(MITSUEA
1.0 kw1.2 kW)
TvpeCommutator mica depthCommutator runoutCommutator O.D.Brush lengthBrush spring tension (new)
N (ksf, lbf)
Gear reduction0.4 - 0.5 (0.016 - 0.020) 0.15(0.006)
o o.o2 (o - 0.000e) | o.o5 (o.oo2)
28.0-28.1 (1.102 1.106) | 27.5(1.083)
15.8 - 16.2 10.62 - 0.64) 11.0 (0.43)
15.7 - 11 .1
{1.60 - 1.80, 3.5 - 4.0i
3-19

Rocker Arms and Shafts
Clearance Inspection
Measure both the intake rocker shaft and exhaust rocker
shaft.
1. Measure the diameter of the shaft at the first rocker
locatron.
2. Zero the gauge to the shaft diameter'
I
3. Measure the inside diameter of the rocker arm and
check for an out of-round condition.
Rockel Arm-to-Shaft Clearance
Standard (Newl:
lntake: 0.017 - 0.050 mm
{0.0007 - 0.0020 inl
Exhaust: 0.018 - 0.054 mm
(0 0007 - 0 0021 in)
Service Limit:0.08 mm {0.003 inl
Repeat these measurements on all the rockers.
- lf the clearance is over the service limit, replace the
rocker shaft and all over tolerance rocker arms.
6-35

Valve Guides
lntake Valve Dimensions
A Standsrd lNewl: 29.9 - 30.1 mm
B Standard (New):
C Standald {Newl:
C Service Limit:
D Standard (New):
D Service Limit:
11.18 - 1.19 inl
117.42 - 117.72 mm
(4.523 - 4.635 inl
5.'18 - 5.49 mm
{0.2r57 - 0.2r61 in)
5.,[5 mm (0.21,16 in]
0.85 - 1.15 mm
(0.033 - 0.0'15 in)
0.65 mm (0.026 in)
Exhaust Valve Dimensions
A Standard lNew): 25.9 - 26.1 mm
B Standard {Newl:
C Standard {New):
C Service Limit:
D Standard {New):
D Service Limit:
(1.02 - 1.03 in)
114.60 - 114.90 mm
11.512 - 4.521in1
5.i[5 - 5.46 mm
10.21lt6 - 0.2150 inl
5.,12 mm 10.213'l in)
1.05 - 1.35 mm
{0.041 - 0.053 in)
0.95 mm {0.037 in}
Valve Movement
Measure the guide-to-stem clearance with a dial indi-
cator while rocking the stem in the direction of normal
thrust (wobble method).
lniake Valve Stem-to-Guide Clearance:
St8ndard lNew): 0.04 - 0.10 mm
10.002 - 0.004 in)
Service Limit: 0.16 mm 10.006 in)
Exhaust Valvs Stem-to-Guide Glearance:
Standard {New}: 0.10 - 0.16 mm
10.004 - 0.006 in)
Sorvice Limit 0.22 mm (0.009 in)
O/'-_)
. lf the measurement exceeds the service limit,
recheck using a new valve.
. lf the measurement is now within the service
limit, reassemble using a new valve.
. lf the measurement still exceeds the limit,
recheck using the alternate method below, then
replace the valve and guide, if necessary.
NOTE: An alternate method of checking guide to
stem clearance is to subtract the O.D. of the valve
stem, measured with a micrometer, from the l.D. of
the valve guide, measured with an inside
micrometer or ball gauge. Take the measurements
in three places along the valve stem and three
places inside the valve guide. The difference be-
tween the largest guide measurement and the
smallest stem measurement should not exceed the
service limit.
lntake Valve Stgm-to-Guidg clearance:
Standard {Newl: 0.02 - 0.05 mm
{0.001 - 0.002 in)
Ssrvico Limit 0.08 mm (0.003 in)
Exhaust Valvo Stem-to-Guide Clearance:
Standard {New): 0.05 - 0.OB mm
{0.002 - 0.003 in)
S€rvice Limit 0.11 mm (o'Ooil in)
Valve extended 10 mm out from seat.
6-39

Cylinder HeadValve Guides
Warpage
NOTE: lf camshaft-to-holder oil clearances (see page 475)
are not within specification, the head cannot be resurfaced.
lf camshaft-to-holder oil clearances are within specifica-
tions, check the head for warPage.
. lf warpage is less than 0.05 mm (0.002 in) cylinder
head resurfacing is not required.
. lf warpage is between 0.05 mm (0.002 in) and 0 2 mm
(0.008 in), resurface cylinder head
. Maximum resurface limit is 0.2 mm (0.008 in) based
on a height of 142 mm (5.59 in).
PRECISION STRAIGHT EDGE
Measure along edges, and three ways across center'
Cylinder Head Height:
Standard lNewl: 1i11.95 - 142.05 mm
15.589 - 5.593 in)
Valve Movement
Measure the guide-to-stem clearance with a dial indica-
tor while rocking the stem in the direction of normal
thrust (wobble method).
lntake Valve Stem-to-Guide Cl6arance:
Standard (Newl: 0.05 - 0.11 mm
(0.0020 - 0.0043 inl
Service Limit: 0.15 mm {0.0059 inl
Exhaust Valve Stem-to-Guide Clealance:
Standard lNewl: 0.10 - 0.16 mm
(0.0039 - 0.0063 inl
Service Limit: 0.24 {0.0094 in)
Valve extended 10 mm out from seat.
lf the measurement exceeds the service limit, recheck
using a new valve.
lf the measurement is now within the service limit.
reassemble using the new valve
lf the measurement still exceeds the limit. recheck using
the alternate method below. then replace the valve and
guide, if necessary.
NOTE: An alternate method of checking guide to stem
clearance is to subtract the o.D. of the valve stem, mea-
sured with a micrometer, from the l.D. of the valve guide,
measured with an inside micrometer or ball gauge.
Take the measurements in three places along the valve
stem and three places inside the valve guide.
The difference between the largest guide measurement
and the smallest stem measurement should not exceed
the service limit.
lntake Valv€ Stem-to-Guide Clsarance:
Standard lNswl: 0.025 - 0.055 mm
10.0010 - 0.0022 inl
service Limit: 0.08 mm (0.003 in)
Exhaust Valve Stem-to Guide Cl€arance:
Standard {Newl: 0.050 - 0.080 mm
{0.0020 - 0.0031 inl
Service Limit 0.ll mm (0.004 in)
6-79

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 Block
Inspection
'LMeasure wear and taper in directions X and y at threelevels in each cvlinder as shown.
Cylinder Boro Size
816A2 engine:
Standard (Newl: 81.00 - 81.02 mm
{3.1t|:l - 3.190 intService Limit: 81.07 mm {3.192 in)D16Y5, D16Y7, D16Y8 engines:
Standard lNew): 75.00 - 75.02 mm(2.9s3 - 2.954 in)
Sarvice Limit: 75.07 mm (2.956 in)
Oversize
816A2 engiDe:
0.25t 41.25 - A1.27 mm {3.199 - 3.200 in)D16Y5, D16Y7, D16Y8 Engines:
0.25t 75.25 -15.27 mm (2.9626 - 2.963,0 in)0.50: 75.50 - 75.52 mm 12.9721- 2.9i32 inl
Bore TaDet
Limit: (Difference between first and third measure"ment) 0.05 mm (0.002 inl
7-16
lf the measurements in any cylinder are beyondthe Oversize Bore Service Limit, replace the block.
lf the block is to be rebored. refer to piston Clear-ance Inspection (see page 7-15) after reboring.
NOTE: Scored or scratched cylinder bores must behoned.
Reboring Limit:
Bl642 enginc:
0.25 mm (0.01 in)
Dl6Y5, D16Y7, D16Y8 engin€s:
0.50 mm (0.02 in)
Check the top of the block for warpage,Measure along the edges and across the center asshown.
SURFACES TO BE MEASUREO
Engine Block Warpage:
Bl6A2 engine:
Standard (Now): 0.05 mm {0.002 inl max.Service Limh: 0.08 mm (0.003 in)DtOYs, D16Y7, D16Y8 €nginas:
Standard (N€w): 0.07 mm l0.OO3 inl max.Servica Limit; 0.10 mm {0.00it in)
PRECISION STRAIGHT EDGE