1999 HONDA CIVIC Intake

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'
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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

6, Remove the camshaft holders. then measure the
widest ponion of the plastigage on each journal.
Camshaft-to-Holder Oil Clearance:
Standard lNew):0.050 - 0.08!t mm
{0.002 - 0.004 in}
Service Limit : 0.15 mm {0.006 in)
lf the camshaft-to-holder oil clearance is out ot tol-
erance:- And the camshaft has already been replaced,
you must replace the cylinder head.
- lf the camshaft has not been replaced, first check
the total runout with the camshaft supported on
V-blocks.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 inl max.
Service Limit: 0.04 mm {0.(X)2 in)
-7.
Rotate camshattwhile measuring.
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- lf the total runout of the camshaft is within toler-
ance, replace the cylinder head.
- lf the total runout is out of tolerance, replace the
camshaft and recheck the camshaft-to-holder oil
clearance. lf the oil clearance is still out of toler-
ance. replace the cylinder head.
INTAKEEXHAUST
O16Y/ engine35.299 (1.3897)37.281 (1.4678)
D16Y5
engrne
PRI38.427 11.5129138.784 (1.5269)
SEC32.193 (1.2674)
D l6Y8
engrne
PRI36.77811.44791
38.008 (1.4964)MID38.274 (1.5068)
sEu37.065 (1.4592)
8. Check the cam lobe height wear.
Cam lobe height standard (New)
t/g a* rN Ex
- D16Y5 engine
PRI; Primary cam lobe, SEC: Secondary cam lobe
MtD: Mid cam lobe. T/B: Timing belt
lN: Intake, EX: Exhaust
PRIsEcMIDSEC
rts
- Dl6YE ongine
Unit mm (in)
Check this area {or wear.
6-37

Cylinder HeadValve Seats
Warpage
NOTE: lf the camshaft-to-holder oil clearances (see
page 6-36) are not within specification, the cylinder head
cannot be resurfaced.
lf the camshaft-to-holder oil clearances are within sDeci,
fications, check the cylinder head lor warpage.
lf warpage is less than 0.05 mm (0.002 in), cylin-
der head resurfacing is not required.
lf warpage is between 0.05 mm (0.002 in) and
0.2 mm {0.008 in), resurface the cylinder head.
Maximum resurface limit is 0,2 mm (0.008 in)
based on a height of 93 mm (3.66 in).
Measure along edges, and three ways across center.
Cylinder Head Height:
Standard {Newl: 92.95 - 93.05 mm
{3.659 - 3.66:} in)
6-40
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Reconditioning
'1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf the guides are worn (see page 6-39).
replace them (see page 6-41) belore cutting the
valve seats.
VALVE SEATCUTTER(Commercially available)
2.
?
4.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutter
and the lower edge of the seat with the 60' cutter.
Check the width of the seat and adjust accordingly.
Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard (N€w):
Intake: 0.85 - 1.15 mm 10.033 - 0.045 in)
Exhaust: 1.25 - 1.55 mm {0.049 - 0.061 in}
Sorvice Limit:
Intake: 1.6 mm (0.063 inl
Exhausl: 2.0 mm (0.079 in)
Seat Width
5. After resurfacing the seat, inspect for even valve
seatingr Apply Prussian Blue compound to the
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against
the seat several times.

Valve Guides
7.
VALVESEAT
PFUSSIAN BTUE COMPOUNO
The actual valve seating surface. as shown by the
blue comDound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 60'cutter to
move it down, then one more cut with the 45'
cutter to restore seat width,
. lf it is too low (closer to the vslve edge), you
must make a second cut with the 30" cutter to
move it uD, then one more cut with the 45'cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45" cutter.
lnsert the intake and exhaust valves in the head and
measure the valve stem installed height.
Intake. Exhau3t Siem Installsd Height:
Standard (New): 53.17 - 53.6,4 mm
12.093 - 2.112 in)
Sorvice Limit: 53.89 mm (2.122 in)
lf the valve stem installed height is over the service
limit. reDlace the valve and recheck. lf its still over
the service limit, replace the cylinder head; the
valve seat in the head is too deep.
VALVE STEMINSTALLED HEIGHT
8.
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Replacement
1.As illustrated below, use a commercially-available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. In most cases.
the same procedure can be done using the special
tool and a conventional hammer.
VALVE GUIDE DRIVERlCommerciallv available)5.3 mm
87 mm +- 57 mft
t3.43 in) | 12 24 inl
tr-r'10.8 mm(0.42 inl
or
VALVE GUIDE DRIVER, 5.5 mm
07742 - 0010100
Select the proper replacement guides. and chill them
in the freezer section of a refrigerator for about an
nour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150'C). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F (150"C1;
excessive heat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
{cont'd)
6-41

Valve Guides
Replacement (cont'd)
Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (0.1 in)towards the combustion chamber. This will knock offsome of the carbon and make removal easier.
CAUTION:
. Always wear satety goggles or a face shield when
driving valve guides.
. Hold the air hammer directly in line with thevalve guide to prevent damaging the driver.
Turn the head over, and drive the guide out towardthe camshaft side of the head.
VALVE GUIOE ORIVER,5.5 mm07742 - 001 01 00
It a valve guide still won't move, drill it out with a8 mm {5/16 in) bit, then try again.
CAUTION: Drill guides only in extreme cases; you
could damage the cylinder head it the guide breaks.
6. Remove the new guides from the freezer, one at atime, as you need them.
6-42
I7. Apply a thin coat of clean engine oil to the outsideof the new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified insralled height. lfyou have all 16 guides to do, you may have to reheat
the head.
VALVE GUIOEDRIVER,5.5 mm07742 - 0010100
ll
Valve Guide lnstalled Height:
Intake: 17.85 - 18.35 mm (0.703 - 0.722 inl
Exhausi: 18.65 - 19.15 mm (0.734 - 0.754 in)
VALVE GUIDE

Valves
Reaming
NOTE: For new valve guides only.
1. Coat both the reamer and valve guide with cufting
orl.
2. Rotate the reamer clockwise the full length of the
valve guide bore.
3. Continue to rotate the reamer clockwise while
removing it from the bore.
4. Thoroughly wash the guide in detergent and water
to remove any cutting residue.
5. Check the clearance with a valve (see page 6-391.
Verify that the valve slides in the valve guide with-
out exerting Pressure.
Turn reamer inclockwise direclionon ly.
REAMER, 5.5 mmO7HAH. PJ'O'IOB
I
REAMER
oa)o,
o
o
1.
lnstallation
Coat valve stems with engine oil. Insert the valves
in the valve guides.
NOTE: Make sure lhe valves move up and clown
smoothly.
lnstallthe spring seats on the cylinder head.
Install the valve seals using the valve guide seal
installer.
NOTE: Exhaust and intake valve seals are not inter-
changeable.
2.
3.
WHITESPRINGBLACKSPRING
INTAKE VALVE SEALEXHAUST VALVE SEAL
VALVE GUIDE SEALINSTALLERKD2899 (Commercially available)NOTE: Use small lD end of
P
(cont'd)
6-43

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
\-
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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.
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10.

Valve Clearance
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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:
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