1998 HONDA CIVIC Valve clearance

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

Valve Clearance
I
I
I
Adjustment {cont'd)
5. Tighten the locknut and recheck clearance.Repeat adjustment if necessary.
Rotate the crankshaft 180. counterclockwise(camshaft pulley turns 90'). The "Up" mark shouldbe on the exhaust side. Adjust valves on No. 3 cylin-der.
Number 3 piston at TDC:
FE€LER GAUGE
"UP- MARKS
6-58
7. Rotate the crankshaft '180. counterclockwise tobring No. 4 piston to TDC. The ,,Up,. mark shouldbe pointing straight down. Adjust valves on No. 4cylinder.
Number 4 piston at TDC:
8, Rotate the crankshaft 180. counterclockwise tobring No. 2 piston to TDC. The "Up., marks shouldbe on the intake side. Adjust valves on No. 2 cylin_der.
Number 2 piston at TDC:
L

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

7. Apply a thin coat of clean engine oil to the outside
of the new valve guide. Install the guide from the
camshaft side of the head; use the special tool to
drive the guide in to the specified installed height. lf
you have all l6 guides to do, you may have to reheat
the head,
VALVE GUIDE DRIVER,5.5 mm077i12 - (x)l01(x)
tr A\
Valve Guide Installed Hoight:
lntake: 12.55 - 13.05 mm {0.,194 - 0.514 in)
Exhaust: 12.55 - 13.05 mm 10.494 - 0.51'l in)
VALVE GUIDE
\
Reaming
NOTE: For new valve guides onlY.
1. Coat both reamer and valve guide with cufting oil.
2. Rotate the reamer clockwise the full length of the
valve guide bore.
Continue to rotate the reamer clockwise while
removing it from the bore
Thoroughly wash the guide in detergent and water
to remove any cutting residue.
Check clearance with a valve lsee page 6-73)
. Verify that the valve slides in the intake and
exhaust valve guides without exertlng pressure.
REAMER HANDLE
Turn r6amer in
clockwise direction
a
VALVE GUIOE REAMER. 5.5 mm
OTHAH - PJTO1IIB
6-81

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.

Troubleshooting
DTClMlL indicationlDatection hsmProbablo CausePage
P0137(63)Secondary Heated Oxygen SensorCircuit Low Voltage(Sensor 2)
Short in Secondary HO2S lSensor 2) circuitSecondary H02S {Sensor 2)ECM/PCI\41 1-153
P0r38 {63)Secondary Heated Oxygen SensorCircuit High Voltage(Sensor 2)
Open in Secondary HO2S (Sensor 2) circuitSecondary HO2S (Sensor 2)EC[I/PCM11-154
P0'139 (63)Secondary Heated Orygen SensorSlow Response(Sensor 2)
Secondary H02S lSensor 2)1l-156
P0141 (65)
Secondary Heated Oxygen SensorHeaterCircuit Malfunction(Sensor 2)
. Open or short in Secondary HO2S (Sensor2) heater circuit. ECM/PCM11-157
P0171 (45)
System Too LeanFuel supply systemPrimary HO2S (Sensor 1)MAP sensorContaminated fuelValve clearanceExhaust leakage
11,164
P0172 (45)
System Too RichFuel supply systemPrimary HO2S (sensor l)MAP sensorContaminated fuelValve clearance
11-164
P0300*16' }l?
andsome ofPo3o1 /r'' \P0302 l72lP0303 l73lP0304 \7 4l
Random Misfirelgnition systemFuel supply systemMAP sensorEGR systemIAC valveContaminated fuelLack of fuel
r1-r66
P0301P0302P0303P0304
/rt\172ll73l\7 4l
- Cylinder 1- Cylinder 2- Cylinder 3- Cylinder 4Misfire Detected
Fuel InjectorFuel Injector circuitlgnition systemLow compressionValve clearance
11 167
P0325*3 (23)Knock Sensor (KS) CircuitMalfunctionOpen or short in Knock Sensor (KS) circuitKnock Sensor {KS)ECM/FCtvl11-170
P0335(4)Crankshaft PositionSensor CircuitMalfunction
Crankshaft Position SensorCrankshaft Position Sensor circuitECM/PCM11-172
P0336(4)Crankshaft PositionSensorRange/Performance
. Crankshaft Position Sensor. Timing belt skipped teeth11-172
P040'r*r (80)Exhaust GasRecirculationInsufficient Flow Detected
' EGR valve. EGR line
P0420(67)Catalyst SystemEfficiency BelowThreshold
. Th.ee Way Catalytic converter. Secondary HO2S11 253
Diagnostic Trouble Code (DTCI Chat (cont'dl
*3: D16Y5 engine (CVT), D16Y8 engine and B1642 engine*4: D'16Y5 engine*16: '98 model+17: '99 - 00 models
,Jla
1 1-98

PGM-FI System
Fuel Supply System
D017-il Th""""ntool indicates Diagnostic Troubte Code {DTC) p0171;Thefuet system istoo lean.
1P0172 | fne scan tool indicates Dlagnostic Trouble Code (DTC) P0172:Thefuel system istoo rich.
Description
By monitoring the Long Term Fuel Trim, long term malfunctions in the fuel system will be detected.lf a malfunction has been detected during two consecutive trips, the MIL will come on and DTC P0171 and/or P0172 will bestored.
NOTE: lf some of the DTCS listed below are stored at the same time as DTC P0171 andlot P0172, ltouhleshoot those DTCSfirst. then recheck for DTC P0l7l andlot P0172.
P0106-8, P1128*3. *5, P1129*3 *5 MAP Sensor
P0135; Primary HO2S Heater
P0137. P0138: Secondary HO2S
P0'141: Secondary HO2S Heater
P0401: EGR Flow Insufficient*1
P0441: EVAP System Insufficient Purge Flow*6
P1259: VTEC System*,
P1491:EGR Valve Lift Insufficient*r
P1498: EGR Valve Lift Sensor Hjgh Voltage*r
*r: D16Y5 engines*': Dl6Y5, D16Y8, 81642 engine*3: '97 models*a:'96 modelsf 5: '98 - 00 models*6: '96 D16Y5 engine,'96 D16Y7 engine,'96 D16Y8 engine (sedan),'97 D16y5 engine,,97 D16y7 engine (coupe: KA, KC mo+els, sedan KA. KC, KL (DX) models. hatchback; all models),'97 D16Y8 engine (sedan: KA, KC models)
Possible Cause
DTC P0'171
loo lean
DTC P0172
too rach
Fuel Pump insuff icient f lovpressure
Fuel Feed Line clogged, leaking
Fuel Pressure Regulator stuck open
Fuel Filter clogged
Fuel Injector clogged, air inclusion
Gasoline doesn't meet Owner's Manual spec.
Primary HO2S (Sensor 1) deteriorated
MAP Sensor range/performance*.
EGR System malfunction (too much flow)*1
Valve Clearance
Exhaust leak
Fuel Pressure Regulator clogged, stuck closed
Fuel Return Pipe clogged
Fuel Injector leaking
Gasoline doesn't meet Owner's Manual spec.Primary HO2S (Sensor 1) deteriorated
MAP Sensor range/performance*a
EGR System insufficient flow*1
EVAP Purge Control Solenoid Valve leaking, stuck opened
Valve Clearance
11-164

PGM-FI System
Random Misfire
lFoioo l*u o, [FTioo l*' *' and
The scan tool indicates Diagnostic Trouble Code (DTC)
P0300*5 or P1300*3 *1 and some of P0301 - P0304:Random misfire.Description
Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKF) sensorwhich is attached to the crankshaft.
lf misfiring strong enough to damage the catalyst is detected. the MIL will blink during the time of its occurrence, and DTCP0300*5 or P1300*3'*' and some of DTCs P0301 through P0304 will be stored. Then, after misfire has ceased, the MIL willcome on.
lf misfiring that increases emissions is detected during two consecutive driving cycles, the MIL will come on, and DTCP0300*5 or P1300*3 *a and some of DTCS P0301 through P0304 will be stored.NOTE: lf some of the DTCS listed below are stored at the same time as a misfire DTC. troubleshoot those DTCS first, thenrecheck for the misfire DTC.
P0106*4. P0107. P0108, P1128*3 *5, Pl129*3 *5; MAP sensorP0131. P0132: HO2S
P0171, P0112i Fuel metering
P0401, P 1491, P1498: EGR svstem*1P0505: ldle Control SystemP1253: VTEC System*,P1361, P1362: TDC sensorP1381, Pl382: CYP sensorP1508: IAC valve
Possible Cause. Fuel pump insufficient fuel pressure, amount of flow. Fuel line clogging, blockage, leakage. Fuel filter clogging. Fuel pressure regulator stuck open. EGR system malfunction*1. Distributormalfunction. lgnition coil wire open. leakage *l: D16Y5 engine. lgnition control module malfunction *2: D16Y5, D16Y8, Bt6A2 engine. MAP sensor range/performance, poor response*r *3: '97 models. Valves carbon deposit *4;'96 models. Compression low *5: '98 - 00 models. IAC valve malfunctionr.. VTEC system malfunction*,. Fuel does not meet Owner's Manual spec., lackoffuel. HO2S. HO2S circuit
Troubleshooting
By test-driving, determine the conditions during which misfire occurs, Depending on these conditions, test in the orderdescribed in the table below.
Possible
- --^ ---
rage
causeEGR*1
system
Crankshaft
position (CKP)
sensor
Fuel
pressure
Distributor and
lgnition wirestcMClearance
tAc
ValveMAP
sensor
section 611-230,
231section 23section 23section 611-19411
Only low rpm and
loado@@oo
Only accelerating@o@@
Only high rpm and
toaooo@
Not specificoo@
NOTE: lf misfire doesn't recur, some possible causes are fuel that doesn't meet owne/s manualspec, lack of fuel, carbon deposits on spark plug, etc.
1 1-1 66
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P0304