1996 HONDA CIVIC Kg max

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

tl
Engine Coolant Refilling and Bleeding
CAUTION: when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical parts or the paint. lf any coolant spills, rinse it
off immediately.
1. Slide the heater temperature control lever to maxl-
mum heat. Make sure the engine and radiator are
cool to the touch.
Remove the radiator caP.
Loosen the drain plug, and drain the coolant'
Remove the drain bolt from the cylinder block'
D16Y5. D16Y7, Dl6Yg sngines:
DRAIN PLUG
0d
I ro
78 N.m {8.0 kgl m.58lbt'ft)
6.
1.
B1642 engin€:
WASHERReplace.
DRAIN BOLT78 N m (8 0 kgf m' 58lbfft)
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten 't
securely.
Tighten the radiator drain plug securely
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
10-7
MAX MARK

Emission Gontrol System
System Description
The emission control system includes a Three Way Cata-lytic Convener (TWC), Exhaust Gas Recirculation (EGR)
system,. Positive Crankcase Ventilation (pCV) system andEvaporative Emission (EVAP) Control system. The emis-sion control system is designed to meet federal and stateemission standards.*: D16Y5 engine
Tailpipe Emission
Inspestion
@@ Do not smoke during ihis procedure. Keepany open flame away from your work area.
1. Start the engine. Hold the engine at 3,000 rpm withno load (in Park or neutral) until the radiator fancomes on. then let it idle.
2. Connect a tachometer.
Check and, if necessary, adjust the idle speed (see
page 11-220 - 223).
Warm up and calibrate the CO meter according to themeter manufacturer's instructions.
Check idle CO with the headlights, heater blower,rear window defogger, cooling fan, and air condition-er off.
NOTE: (Canada) Pull the parking brake lever up.Start the engine, then check that the headlights areoff.
CO mete. should indicate 0.1% maximum.
NOTE: '98 Dl6Y5 engine - lf the idle speed incress-es to 8101 50 rpm, this means the EVAp system ispurging the canister. To stop the purging temporari-ly. raise the engine speed above 1,000 rpm with theaccelerator pedal, then slowly release the pedal.
11-252
eFORWARD -
Three Way Catalytic Converter
(TWCI
Doscription
The Three Way Catalytic Converter (TWC) is used toconven hydrocarbons (HC), carbon monoxide (CO), andoxides of nitrogen (NOx) in the exhaust gas to carbondioxide (COr), dinitrogen (N,) and water vapor.
D15Y5, D16
, engine:
'99 - 00 D16Y8, 81642 engine:
ENGINE SIDE
t

Pressure Plate
\Removal/lnsPection
1.Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard {New}: 0.6 mm (0.02 inl max.
Seruice Limit: 1.0 mm {0.04 in}
FEELER GAUGE
CLUTCH ALIGNMENT DISCOTJAF_PM7O1 1ACLUTCH ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-37tOtOO
lf the height exceeds the service limit, replace the
pressure Plate.
3. Installthe special tools
PRESSURE PLATE
MOUNTINGBOLT
ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-371010Oo7924-PD20003GEAR HOLDER
07LA8-PVOOIOOot
ENGINEBLOCKADJUSTER BOLT
BOLT
4. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
f
12-7
lnspect the pressure plate surface for wear' cracks,
and burning.
Inspect for warpage using a straight edge and leeler
ga uge.
NOTEr Measure across the pressure plate at three
pornrs.
Standard (Newl: 0.03 mm (0.001 inl max.
Service Limit: 0.15 mm (0.006 inl
lf the warpage exceeds the service limit, replace the
pressure plate.
STBAIGHT EDGE

Flywheel
\Inspection
1.
2.
3.
Inspect the ring gear teeth for wear and damage
Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
Measure the flywheel runout using a dial indicator
through at least two full turns Push against the
flywheel each time you turn it to take up the
crankshaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (New): 0.05 mm (0.002 inl max.
Service Limit: 0.15 mm {0.006 in)
FLYWHEEL
OIAL INOICATOR
FLYWHEEL
lf the runout exceeds the service limit. replace the
flywheel.
Turn the inner race o{ the ball bearing with your tin-
ger. The ball bearing should turn smoothly and qui
etly. lf the inner race does not turn smoothly and
quietly, replace the bearing. Check that the ball
bearing outer race fits tightly in the flywheel. lf it is
loose. replace the ball bearing
IJ
4.
BALL BEARING tO
Replacement
1. Installthe special tool.
MOUNTINGBOLTS
RITIG GEAR HOLDER
oTLAB-PV00100oto7924-PD20003
2.Remove the flywheel mounting bolts in a crisscross
pattern in several steps as shown, and remove the
flywheel,
Remove the ball bearing from the flywheel
(cont'dl
12-9
FLYWHEEL
t\
m\J

Mainshaft Assembly
Disassembly (cont'd)
3. Support the 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub as shown.
13-18
Inspection
'1. Inspect the gear surface and bearing surface for
wear and damage. then measure the mainshaft atpoints A, B, C, and D.
Siandard: A: 21.987 - 22.000 mm
10.8656 - 0.8661 inl
B: 26.980 - 26.993 mm
11.0622 - 1.0627 inl
C: 33.98,1- 34.000 mm(1.3380 - 1.3385 in)
D: 25.977 - 25.990 mm
|.1.0227 - 1.0232 inl
Service Limit: A: 21.930 mm 10.8634 inl
B: 26.930 mm {1.0602 in}
C: 33.930 mm (1.3358 in)
D: 25.920 mm (1.0205 in)
Check for wear and damage
lf any part of the mainshaft is less than the service
limit, replace it with a new one.
2. Inspect for runout.
Standardi 0.02 mm (o.(Xtl in) max.
S€rvice Limii: 0.05 mm (0.002 in)
NOTE: Support the mainshaft at both ends as
snown.
lf the runout is more than the service lirnit, reolace
the mainshaft with a new one.
Y

Inspection
1.surfaces lor
countershaftInspect the gear surfaces and bearang
wear and damage, then measure tne
at points A, B, and C.
Standard: A: 30.000 - 30.015 mm
(1.1811- 1.1817 inl
B: 35.984 - 36.000 mm
(1.i1167 - 1.4173 inl
C: 24.980 - 2i1.993 mm
{0.9835 - 0.9840 in)
Seryice Limit: A: 29.950 mm (1.1791 inl
B: 35.930 mm (1 '1146 in)
C: 24.930 mm 10.9815 in)
Check oil passages
for cloggrng-
ICheck for wearano oamage.
. lf any part of the countershaft is less than
service limit, replace it with a new one.
Inspect for runout.
Standard: 0.02 mm (0.001 inl max.
Seryice Limit: 0.05 mm {0'002 in)
. lf the runout is more than the service limit. replace
the countershaft with a new one.
the
2.
t,3. Install the parts on the countershait
Reassembly
CAUTION:
. Press the 3rd,4th, and sth gears on the countershaft
without lubrication.
. When installing the 3rd. 4th, and 5th geals, support
the shaft on steel blocks and installthe gears using a
pless.
NOTE: Reler to page 13-20 for reassembly sequence'
1. lnstall the needle bearing on the countershaft'
, 36x41 x 25.5mmNEEDLE BEARING
COUNTERSHAFT
2. Assemble the pans below as shown.
NOTE: Check that the fingers of the friction damper
are securely set in the grooves of the 1sv2nd syn-
chro hub.
2ND GEAR
39x/+4x27mmNEEDLE BEARING
SPACER COLLAR
FRICTION DAMPER
SYNCHRO RING
SYNCHRO SPRING
REVERSE GEAR
lST/2NOSYNCHRO HUB
SYNCHRO SPRING
SYNCHRO RING
FRICTION DAMPER
1ST GEAR
(cont'd)
13-23