1996 HONDA CIVIC Engine head

Gylinder Head/Valve Train
816A2 engine
Special Tools ............. 6'50 Rocker Arms
VTEC Contlol System
Troubfeshooting Flowchart ............ 6-51 Disassembly/Reassembly ...............6'72
VTEC Solenoid ValveRocker Arms and Lost Motion Assemblies
Inspection ...""'...... 5-54 Inspection .........""' 6-73
VTEC Rocker ArmsRocker Arms and Shafts
Manual Inspection ........................... 6-54 Clearance Inspection ..'..."'.............. 6-74
Inspection Using Special Tools .....' 6-55 Camshafts
Valve Clearance
.^ Adiustment .........." 6-57 Valves'Valve Springs and Valve Seals
. t Crankshaft Pulley and Pulley Bolt Removal """"""""' 6-77
Replacement ..".....6-59 Valve Seats
Timing BeltReconditioning ......6'78
Cylinder Headlnstallation '............ 6-82

VTEC Solenoid ValveVTEC Rocker Arms
a
I
(
Inspection
1. Remove the VTEC solenoid valve assembly fromthe cylinder head. and check the VTEC solenoidvalve filter for clogging.
. lf there is clogging, replace the engine oilfilter andengine oil.
6x1.0mm12 N.m (1.2 kgf.m, B,7 tbf.ftl
lf the filter is not clogged. push the VTEC solenoidvalve with your finger and check its movemenr.
. lf the VTEC solenoid valve is normal, check theengine oil pressure.
6x1.0mm12 N.m (1.2 kgtm,8.7 lbt.ft)
6-54
L-
SOLENOID
Manual Inspection
1. Set the No. 1 piston at TDC.
2. Remove the ignition wire cover and the wires.
3. Remove the ignition clamps while pulling up on theIock.
6xl.0mm9.8 N.m (1.0 kgl.m, 7.2 tbtftl
IGNITIONWIRE COVER
IGNITIONWIRE
\
LOCK

Inspection
Remove the cylinder head cover.
NOTE: Refer to page 6-86 when installing the cylin-
der head cover.
Inspect the timing belt for cracks and oil or coolant
soakrng.
NOTE:
. Replace the belt if oil or coola nt soaked.
. Remove any oil or solvent that gets on the belt'
I
Rotate PUlleYand inspect belt-
After inspecting, retorque the crankshaft pul
to 177 N.m (18.0 kgf'm, 130 lbf'ft)
'L
lnspect thrs area
Tension Adiustment
CAUTION: Always adiust timing belt tension with the
engine cold.
NOTE:
. The tensioner is spring-loaded to apply proper ten
sion to the belt automatically after making the follow-
ing adjustment.
. Always rotate the crankshaft counterclockwise when
viewed from the pulley side. Rotating it clockw'se
may result in improper adjustment of the belt ten-
sion.
1, Remove the cylinder head cover.
NOTE; Refer to page 6-86 when installing the cylin-
der head cover.
2. Set the No. 1 piston at TDC (see page 6-64)
3. Rotate the crankshaft live or six revolutions to set
the belt.
4. Set the No. 1 Piston at TDC
ADJUSTING BOLT
54 N.m(5.5 kgt.m, a0 lbtftl
5.
7.
8.
Loosen the adjusting bolt 180'.
Rotate the crankshaft counterclockwise three teeth
on the camshaft PulleY.
Tighten the adjusting bolt.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf'm, 130 lbnft)
ley bolt
6-61

Cylinder Head
lllustrated Index
CAUTION:
. To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F (38"C1 bofote
removing it,
. when handling a metal gasket, take caro not to fold the gaskot or damage the contact surface of the gasket.
NOTE: Use new O-rings and gaskets when reassembling.
CYLINDER HEAO
PLUGReplace.
)@
DISTRIBUTOR
8 x 1 ,25 mm
27 N.m P.E kgl m.
20 tbf.foApply engine oil to
the threads.
cr.rMp.S
CAMSHAFT A"o''*t*'; wes@
OIL SEALReplace.
6 x l,omm9.8 N'm tl.0 kgt'm,7.2lbf ft)
RUBBER SEALReplace when damaged
or detedorated.
6x1.0mm9.8 N.m (1.0 kgf'm,
7.2 rbnftl
fi%
IGNMONWIRE COVER
CYLINOER HEAD
COVERRefer to page 6-86
when installing
HEAD COVER GASKETReplace when leaking, damaged
or deteriorated.Apply liquid gasket at thecorners of the recesses, Page 6-86
8 x 1,25 mm24 N.m {2.4 kgf'm,
1? tbf.ftl
EXHAUST
10 x 1.25 mm56 N.m (5.7 kgf m,,r1 lbl.ft)
(cont'd)
6-65

Cylinder Head
lllustrated Index (cont'dl
CYLINDER HEADBOLTS11 x 1.5 mm83 N.m {8.5 kg{.m, 61Apply engine oilto threads.
INTAKE VALVE SPRING INNER
VALVE KEEPERS
SPRING RETAINER
INTAKE VAI.VE SPRING OUTER
valvEKEEPEBS\:""j"*'
SPRING RETAINER
EXHAUST VALVESPRING
VALVE SEALReplace.
VALVE
LOST MOTIONASSEMBLY
EXHAUST VAL
VALVE SEALReplace.
SPRING SEAT
VALVE GUIDE
INTAKE VALVE
ROCKER SHAFT
SEALING AOLTS.20 mm64 N.m (6.5 kgt.m, 47 tbf.ft)
t
il
HEAO OIL CONTROLORIFICEClea n.
a
6-66

Removal
Engine removal is not required for this procedure.
!@@ Make sure jacks and safety stands are placed
properly and hoist brackels are attached to correst posi-
tion on the engine,
CAUTION:
o Use fender covers to avoid damaging painted sur-
faces.
To avoid damage, unplug the wiling connectors
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F {38'Cl
before loosening the retaining bolt.
NOTE:
. Unspecified items are common.
. Mark all wiring and hoses to avoid misconnection.
AIso, be sure that they do not contact other wiring or
hoses or interfere with other parts.
o Inspect the timing belt before removing the cylinder
n eao.
. Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (see page 6-64).
1. Disconnect the negative terminal from the battery.
Drain the engine coolant {see page 10-7).
. Remove the radiator cap to speed draining.
Remove the strut brace (see page 5-2).
Remove the intake air duct and air cleaner housing
(see page 5-3).
Remove the adjusting bolt and mounting bolt, then
remove the power steering (P/S) pump belt and pump
(see page 5 5).
2.
3.
4.
\
ADJUSTING
6. Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (A/C) com-
pressor belt.
IDLER PULLEY BRACKETBOLT10 x 1.25 mm44 N.m {4.5 kg,l.m, 33 lbt.ft}
7. Loosen the mounting nut and lock bolt, then remove
the alternator belt.
LOCK BOLT8 x 1.25 mm24 N.m {2.4 kgf.m,17 tbtftl
ALTERNATORBELT10 x 1.25 mm,l,l N.m {4.5 kgf.m,33 tbf.ft,
(cont'd)
6-67

WATER BYPASS
HOSE
14. Remove the upper radiator hose, heater hose and
water bvpass hose.
HEATER
Remove the engine wire harness connectors and wlre
harness clamps from the cylinder head and the intake
manifold.
Four fuel injector connector
Engine coolant temperature (ECT) sensor connec-
tor
ECT gauge sending unit connector
ECT switch connector
ldle air control (lAC) valve connector
Manifold absolute pressure (MAP) sensor connec-
tor
Throttle position sensor connector
Primary Heated oxygen sensor (Primary HO2S)
connecror
VTEC solenoid valve connector
15.
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a
a
a
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16.
17.
Remove the spark plug caps and distributor form
the cylinder head.
Remove the upper bracket.
NOTE:
. Use a jack to support the engine before removing
the upp€r bracket is removed.
. Place a cushion between the oil panandthejack.
12 x 1.25 fin74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cylinder head cover.
{cont'd)
6-69

Camshafts
Inspection
NOTE:
. Do not rotate the camshaft during inspection.
. Removg the rocker arms and rocker shafts.
'L Put the camshafts and camshaft holders on the cylin-
der head. and then tighten the bolts to the specified
torque.
Specified Torque:
O -@: 8 mm botts 27 N.m {2.8 kgf.m,20 lbt'ft)
Apply engine oil to the threads,
O - @: 6 mm bolts 9.8 N.m (1.0 kgf m, 7.2 lbf'ft)
Seat the camshaft by pushing it toward the distribu-
tor end of the cylinder head.
Zero the dial indicator against the end of the distrib-
utor drive. then push the camshaft back and fonh
and read the end play.
Camshaft End Play:
Standard {New}: 0.05 - 0.15 mm
{0.002 - 0.006 inl
Service limil: 0.5 mm (0.02 in)
ooooooo
ooooo
\-
4.Remove the bolts. then remove the camshaft hold-
ers from the cylinder head.
- Lift the camshaft out of the cylinder head, wipe
clean, then inspect the lift ramps. Replace the
camshaft if lobes are pitted, scored, or excessively
- Clean the camshaft bearing surfaces in the cylin
der head, then set the camshaft back in place,
- Insert a plastigage strip across each iournal.
Put the camshaft on the cylinder head. then install
the camshaft holders, and then tighten the bolts to
the specified torque as shown in the left column on
this page.
Remove the camshaft holders, then measure the
widest portion of the plastigage on each journal.
Camshaft -to-Hold€1 Oil Clearsnce:
Standard {Newl: 0.050 - 0.089 mm
{0.002 - 0.004 inl
S6rvice Limit: 0.15 mm 10,006 inl
(cont'd)
6-75
PLASTIGAGE STRIP