1996 HONDA CIVIC gap

MEASUREMENT
,n7 _--
STANDAFO INEW}
0.07 10.003) max.75.00 75.02 (2.953 - 2.954)
7 4.9A0 7 4.990 t2.9520 2.95241
0.010 - 0.040 (0.0004 0.0016)1.020 - 1.030 10.0402 _ 0.0406)1.220 1.230 (0.0480 - 0.0484)2.805 - 2.820 {0.1 104 _ 0.11 tO)
0.035 - 0.060 (0.0014 0.0024)0.030 - 0.055 {0.0012 0.0022)_
0.15 0.30 {0.006 _ 0.012)0.30 - 0.45 (0.012 - 0.018)0.20 - 0.70 10.008 0.028)
18.994 - 19.000 (0.7478 _ 0.7480)0.010 - 0 0?2 lo oona -n dn^ol
SERVICE LIMIT
0.10 (0.004)
75.07 (2.956)0.05 (0.002)0.5 (0.02)
74.970 (2.9516)
0.05 (0.002)1.05 (0.041)
1.2510.049)2.85 (0.112)
0.13 {0.005)0.13 (0.005)
0.60 (0.024)
0.70 (0.028)
ljqql) _
oro to.o',ur
0.005 (0.0002)
0.005 (0.0002)
0.4510.018)0.04 (0.002)
0.05 (0.002)
0.05 {0.002)0.05 (0.002)
Cylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
Skirt O.D. at 5 mm (0.2 in)from bottom of skinClearance in cylinderGroove width {for ring) TopSecondoil
Ring to-groove clearance TopSecondRing end gapTopSecondoil
o.D.Pin-to piston clearance
Pin-to rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
Piston
Piston ring
Piston pin
Connectingrod0.014 - 0.040 (0.0006 _ 0.ool6)18.96 - 18.98 (0.746 0.747)48.011.89)0.15 - 0.30 (0.006 - 0.012)CrankshaftMain journaldiameter
Rod iournaldiameterTaperOut of-roundEnd playTotal runout
Main bearing to-lournal o't clearance-No_ l and 5journals
_ No. 2, 3 and 4 journatsBod bearing to,journat oil ctearance
54.976 - s5.000 (2.1644 - 2.1654)44.91 6 - 45.000 1'1.17 01 _ 1.71 11 10.002510.0001) max.0.0025 (0.0001)max.
0.10 - 0.35 (0.004 0.014)0.03 (0.001) max.Bea.ings
0.018 - 0.036 (0.0007 0.0014)0.024 0.042 (0.0009 - 0.0017)0.020 - 0.038 (0.0008 _ o.oo.t5)
Standards and Service Limits
Engine Block {Dl6Y5, D16Y7, Dt6y8 enginesl - Section
L,
LO
3-4
LO

Section 7
Unlt of length: rnm ( n)
Engine Block(816A2 engine) -
MEASUREMENT
Warpage of deck surface
Bore diameterBore taperReboring limit
STANOARD {NEW)
0.05 (0.002)
8L00 81.02 (3.189 3.190)
SERVICE LIMIT
0.08 {0.03)81.07 (3.192)
0.05 (0.002)
0.25 (0.01)
Cylinder block
PistonSkin O D. At 15 mm (0.6 in)
{rom bottom of skirt
Clearance in cylinder
Groove width (for ring) ToPSecondoil
80.980 - 80.990 (3.lUUz 3. rUubl du Y/u lJ. ro/o,
I0.010 0.040 (o.ooo4 - 0.0016' 0 05 r0 002) II O3O 1.040 10.0406 - 0.04091 1 060 {0 0417) |1.230 - 1.?40 {0.0484 . 0.04881 1.260 10.04961 1'*: ?:::i?l:91'::ll:l I::::::= lPiston ringRing-to-groove clearance
Ring end gap
o.D.Pin to-piston clearance
Pin'to rod interference
Small end bore diameter
Large end bore diameterEnd play installed on crankshaft
Main journal diameterNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod journal diameterTaperOut of roundEnd play
Total runout
Main bearing to_journal oil clearance
No. 1, 2, 4 and 5 journals
No. 3 journal
Bod bearing'to iournal oil clearance
Second
Top
Secondoil
Nominal
0.13 (0.005)
0.1310.005)0.60 (0.024)
0.60 t0.024)0.7010.028)0.70 (0.028)
,rr]q!4l
-l
u.u45 - u.u/u lu.uu ro
0.040 - 0.065 (0.0016 0.0026)*l
0.045 - 0.070 (0.0018 0.0028)*'
0.20 - 0.35 (0.008 - 0.014)*1
o.20 - 0.30 (0.008 - 0.012)*'
0.40 0.55 (0.016 0.022)
0.20 - 0.50 (0.008 - 0.020)*'
0.20 - 0.45 (0.008 - 0.018)"
20.994 - 21.000 {0.8265 - 0.8268)
0.010 - 0.022 (0.0004 0.0009)
0.013 - 0.032 (0.0005 - 0.0013)
20.968 20.981 (0.8255 - 0.8260)
lliSlto?,o.oou o.o''r, o.rotoo'ut
Piston pin
Connecting rod
54.976 55.000 (2.1644 - 2.1654)
54.970 - 54.994 (2.1642 2.1651)
44.976 - 45.00011.'1707 - 1.1711|
0.005 (0.0002) max.0.004 (0.0002) max.0.10 0.35 (0.004 - 0.014)
0.020 (0.0008imax.
0.010 (0.0004)
0.006 (0.0002)
0.45 (0.018)
0.030 (0.0012)
Crankshaft
Eearing0.024 - 0.042 (0.0009 0.0017)
o.o3o - 0.048 {0.0012 0.0019)
0.032 - 0.050 (0.0013 - 0.0020)
0.06 (0.002)
0.06 (0.002)
0.06 (0.002)
*1: RIKEN manutactured prston rrng*2:TEIKOKU PISTON RING manufactured piston ring
gineslSection 8
(cont'd)
Engine Lubri,cation (Dl6Y5, Dl5Y7' Dl6Y8 enginesl -
MEASUREMENTSTANOARD (NEW) S€RVICE LIMIT
4.3 (4.5, 3.8)Ior engine overhaul
3.6 (3.8, 3.2) for oil change, including filter
3.3 (3.5, 2.9) for oil change, without filter
3.7 (3.9,3.3)for engine overhaul
3.3 (3.5, 2.9) for oil change, including filter
3.0 {3.2, 2.6} for oil change, without filter
0.02 - 0.14 (O.OO1 - 0.006) 0.20 {0 008)
0.10 0.18 (o.oo4 - 0.007) i 0.20 (0 008)
o 03 !.08 (qool!.oo3l _ (0 006) -
70 (0.7, 10) min.
340 (3.5,50) min
Engine oilCapacity | (US qt, lmp qt) D16Y7
D16Y5 D16Y8
lnner-to-outer rotor radial clearance
Pump housing to_outer rotor radialclearance
Pumo housrnq_to rotor a)rial clearance
Pressure setting with oil temperature 176'F (80'Ci
kPa (kgf/cm', PsiI at idleat 3,000 rpm
Oil pump
Relief valve
3-5

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

5. With the specified air pressure appli€d, push up the
timing plate; the synchronizing piston will pop out
and engage the intake secondary rocker arm.
Visually check the engagement of the synchronizing
prston.
NOTE;
The synchronizing piston can be seen in the gap
between the secondary and primary rocker arms,
With the timing plate engaged in the groove on
the timing piston, the piston is locked in the
oushed out Dosition.
TIMIiIGPLATESPRIT{C
PRIMARY ROCKER ARM
AIR PRESSURE
GROOVE
SECO DARYROCKER ARM
TIMIT{G PLATE
TIMING SPRING
6-9
6. Stop applying air pressure and push up the timing
plate; the synchronizing piston will snap back to its
original position.
Visually check the disengagement of the synchro-
nizing pistons.
NOTE:
. When the timing plate is pushed up, it releases
the timing piston, letting the return spring move
the synchronizing piston to its original position.
7. Replace the intake rocker arms as an assembly if
either does not work correctly,
TIMING PLATE
oll PASSAGE --!
PRIMARY ROCKER
ARMSECOI{DARYROCKER ARM
TIMII{G SPRII{GRETURI{ SPRING
Remove the spscial tools.
After inspection, check that the malfunction indicator
lamp (MlLl does not come on.
TIMI G PISTOI{

Cylinder Head
Installation (cont'dl
Position the camshaft correctly (see page 6-20).
Tighten the cylinder head bolts sequentially in four
steps.
rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft|
2nd srep: O - @ 49 N.m (5.0 kgf.m, 36 tbtft)
3rd stop; O - @ 67 N.m {6.8 kgf.m, /r9 lbl'ft}
4th st6p: O, O 67 N.m 16.8 kgf.m, 49 tbf.ftl
NOTE:
. We recommend using a beam-type torque
wrench, When using a preset-type torque wrench.
be sure to tighten slowly and not to overtighten.
. If a bolt makesany noisewhileyou aretorquing it,
loosen the bolt, and retighten it from the 1st step,
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Install the intake manifold and tighten the nuts in a
crisscross pattern in two or three steps, beginning
with the inner nuts (see pages 9-2 thru 9-4).
. Always use a new intake manifold gasket.
Install the exhaust manifold and tighten the nuts in
a crisscross pattern in two or three steps, beginning
with the inner nut {see pages 9-6 and g-7).
. Always use a new exhaust manifold gasket.
Install the exhaust manifold bracket. lnstall the
exhaust pipe A and the bracket, then install the cover.
4.
6-46
\-
(
7.Installthe timing belt (see page 6-20).
Adjust the valve clearance (see page el2),
Install the head cover gasket in the groove of the
cylinder head cover, Seat the recesses for the
camshaft first, then work it into the groove around
the outside edges.
NOTE:
. Before installing the head cover gasket, thor-
oughly clean the seal and the groove.
. When installing, make sure the head cover gas-
ket is seated securely in the corners of the
recesses wath no gap.
COBNERS OFTHE RECESS
CORNERS OFTHE REcEss covEB
Apply liquid gasket to the head cover gasket at the
four corners of the recesses.
NOTE:
. Use liquid gasket, Pan No. 08718 - 0001 or 08718- 0003.
. Check that the mating surfaces are clean and dry
before applying liquid gasket.
. Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.
. After assembly, wait at least 30 minutes before
filling the engine with oil.
8.
9.
I
10.

Cylinder Head
Installation (cont'dl
10. Align the marks on the cylinder head plug to thecylinder head upper surface, then install the cylin,
der head plug in the cylinder head.
PLUGReplace.
Install the timing belt (see page 6-63).
Adjust the valve clearance (see page 6-61).
Install the head cover gasket in the groove of the
cylinder head cover. Seat the recesses for the
camshaft first, then work it into the groove around
the outside edges,
NOTE:
. Before installing the head cover gasket, thorough-ly clean the head cover gasket and the groove.
. When installing, make sure the head cover gasket
is seated securely in the corners of the recesses
wrrn no gap.
11.
13.
1'
CYLINDEB HEAD
HEAD COVEB
6-86
(\
14. Apply liquid gasket to the head cover gasket at theeight corners of the recesses.
NOTE:
. Use liquid gasket, Part No. 08718 - 0001 or 08718- 0003.
. Check that the mating surfaces are clean and drybefore applying liquid gasket
. Do not install the parts if five minutes or morehave elapsed since applying tiquid gasket.
Instead, reapply liquid gasket after removing oldrestdue.
. After assembly. wait at least 30 minutes before
filling the engine with oil.

Engine Block
Speciaf Tools ..........." 7-2
lllustlated Index ...................."..'.......... 7-3
Flywheel and Drive Plate
Repf acement """'.' 7-7
Connecting Rod and Crankshaft
End Play ..........."....7-8
Main Bearings
Clearance ............... 7-9
Selection ................7-10
Connecting Rod Bearings
clearance ....'.......... 7-11
Selection ................ 7-11
Pistons and Crankshaft
Removaf ................. 7 -12
Crankshaft
Inspection ."".........7-14
Pistons
Inspection ......"'.....7-15
fnstaffation .............7-23
Cylinder Block
lnspec'tion ..............7-16
Bore Honing ..........7-17
Piston Pins
Removal ...,...........'.7-17
lnstallation .............7-18
Inspection .'............7-19
Connecting Rods
Selection ................7-18
Piston Rings
End Gap ..........".."' 7'2O
Repfacement .........7-2O
Ring-to-Groove Clearance ...........'.'. 7 -21
Afignment .......""'.. 7'21
Crankshaft Oil Seal
fnstaffation .............7-22
Crankshaft
fnstaffation ..-.-..'.".' 7'23
Oil Pan
lnstallation .............7-26
Oil Seals
fnstaffation ....""""' 7-29
r-f

Piston Rings
End Gap
1.Using a piston, push a new ring into the cylinderbore 15 - 20 mm (0.6 - 0.8 in) from the bottom.
Measure the piston ring end-gap with a feeler gauge:
. lf the gap is too small, check to see if you have
the proper rings for your engine.. lf the gap is too large. recheck the cylinder borediameter against the wear limits on page 7-16,
lf the bore is over the service limit, the cvlinderblock must be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd (New): 0.20 - 0.35 mm
{0.008 - 0.01,1 in)
Service Limit: 0.60 mm l0-02i1 inl
D16Y5. Dl6Y7, D16Y8 enginos
Standard lNewl: 0.15 - 0.30 mm
{0.006 - 0.012 in)
Ssrvic€ Limit 0.60 mm {0.024 inl
Socond Ring
816A2 ongina
Standard (Nowl: 0.40 - 0.55 mm
10.016 - 0.022 inl
Service Limit: 0.70 mm (0.028 inl
D16Y5, D16Y7, Dt6Y8 engines
Standard (New): 0.30 - 0.ia5 mm
{0.012 - 0.018 in)
Sorvice Limit 0.70 mm 10.028 inl
Oil Ring
81642 ongine
Standard {Now): 0.20 - 0.50 mm(0.008 - 0.020 inl
Sorvico Limit: 0.70 mm (0.028 in)
Dl6Y5. Dl6Y7, D16Y8 €nginos
Standard (Nowli 0.20 - 0.70 mm(0.008 - 0.028 inl
Servica Limit: 0.80 mm 10.031 in)
7-20
Replacement
1.Using a ring expander. remove the old piston rings.
Clean all ring grooves thoroughly.
NOTE:
. Use a squared-off broken ring or ring groove
cleaner with blade to fit piston grooves.
o Top ring groove is 1.0 mm (0.039 in)wide.. Second ring groove is 1.2 mm (0.047 in) wide.. Oil ring groove is 2,8 mm (0.11 in) wide.. File down the blade if necessary.
CAUTION: Do noi use a wire blush to clean ringlands. or cut ring lands deepol with cleaning tool.
NOTE: lfthe piston is to be separated from the con-necting rod, do not install new rings yet.
3. Install new rings in the proper sequence and posi-
taon (see page 7-22).
NOTE: Do not reuse old piston rings.
(Commercially available)