1999 HONDA CIVIC valve adjustment

Cylinder Head/Valve Train
Dl6Y5, D16Y7, Dl6Y8 engines
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection ............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5 engine) ............................. 6-7
Manual Inspection
(D16Yg enginel ................'............ 6-7
Inspection Using Special Tools
{D16Y5 engine} .....................""'... 6-8
Inspection Using Special Tools
(D16Y8 engine) .........................'.'. 6-10
Valve Clearance
Adiustment ..."".....6-12
Valve Seals
Replacement (Cylinder head removal
not requiredl ................................ 6-1tl
Crankshaft Pulley and PulleY Bolt
Replacement ."...... &16
Timing Selt
lllustrated Index ............................... 6-17
Inspection .............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal ......,,......... 6-19
lnstallation ............. 6-20
Crankshaft Speed Fluctuation (CKF) Sensor
Repf acement .........6'22
Cylinder Head
lllustrated Index ............................... 6-23
Removal ................. 6-27
Warpage ................ 6-40
lnstallation ............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly ............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection (D16Y5, D16Yg
enginesl "..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection .............. 6-36
Valves, Valve Springs and Valve Seals
Removal ........""..... 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement .........6-41
Reaming .......'......'.' 6-43
Valve Seats
Reconditioning .'....6'40
Valves
lnstallation ............. 6-tt3
Camshaft/Rocker Arms and
Camshaft Seal/Pulley
lnstallation ............. 6-44

Valve Clearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylindsrhead temperature is less than 100"F (38"C).
. After adjusting, retorque the crankshaft pulley bolt(see page 6-16).
1, Remove the cylinder head cover.
NOTE; Refer to page e46 when installing the cytinderhead cover.
2. Remove the upper cover (see page 6-19).
3. Set the No. 1 piston at TDC. The "UP" mark on the
cam-shaft pulley should be at top, and the TDC
marks should align with the cylinder head surface.
TDC MARKS
4. Adjust valves on No, 1 cylinder.
Intako: 0.18 - 0.22 mm {0.007 - 0.009 in}
Exhaust: 0.23 - 0.27 mm (0.009 - 0.011 inl
"UP" MARK
6-12
No.4
5. Loosen the locknut, and turn the adjustment screwuntil the feeler gauge slides back and forth with asliOht amount of drag,
D16Y7 engin.:
CAUTION: Do not oyertighlen the locknuts; thorockor arms are made of aluminum.
INTAKE end EXHAUST VALVELOCKNUTS
Dl6Y5, Dl6Y8 engin€3:
INTAKE .nd EXHAUST VALVELOCKNUTS20 N.m 12.0 kstm, 14lbtft)
Adiusting screw locations:
IMTAKEo.4 1{o. 3 No. 2
tr'
(
nb.3 No.2 No. 1EXHAUST
18 N.m (1.8 kgI.m, 13 tbl.ftl

6. Tighten the locknut, and check the clearance again.
Repeat the adjustment if necessary.
GAUGE
7.Rotate the crankshaft 180' counterclockwise (cam-
shaft oullev turns 90'1. The "UP" mark should be on
the exhaust side. Adjust valves on No. 3 cylinder.
"UP- MARK
t
8. Rotate the crankshaft '180' counterclockwise to
bring No.4 piston to TDC. Both TDC grooves are
once again visible. Adjust valves on No. 4 cylinder.
Rotate the crankshaft 180'counterclockwise to bring
No. 2 piston to TDC. The "UP" mark should be on
the intake side. Adjust valves on No. 2 cylinder.
-UP'MARK
6-13

Valve Glearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylinder
head temperaturs is less than 100'F (38'C)'
. After adjusting, retorque the crankshaft pulley bolt to
177 N.m (18.0 kgf'm, 130 lbt'ft)
1. Remove the cylinder head cover'
NOTE: Refer to page G86 when installing the cylin-
der head cover.
2. Set No. 1 pi$on at TDC. The "UP" mark on the pullsy
should be at the top, and TDC grooves on the pulley
should align with the pointer on the back cover' TDC
grooves {white paint) on the crankshaft pulley should
align with the pointer on the timing belt lower cover'
Number I Piston at TDC:
4.
Adjust valves on No. 1 cylinder.
lntako: 0.15 - 0.19 mm {0'006 - 0.007 in)
ExhaGt 0.17 - 0.21 mm {0'007 - 0 008 inl
Loosen the locknut, and turn the adjusting screw
until the feeler gauge slides back and forth with a
slight amount of drag.
TAPPET ADJUSTERWFENCH SET07MM - PR70110
TAPPET LOCKNUTWRENCH07MAA - PR70120
Adiusting sclaw location:
LOCKNUT20 N.m {2.0 kgf'm, lil lbt'ftl
(cont'd)
6-57

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

Component Locations
Index (cont'd)
D16Y5, D16Y8 ongine:
RESONATOR
D16Y7 6ngin€:
AIR CLEANER IACLIReplacement, page 11-244
THROTTLE BODY (TBIInspection, page 1 1-247Removal, page 11-248Disassembly, page 11 249
THROTTLE CABLElnspection/Adjustment. page 1 1 -244
Installation, page 11 245
AIR {FIA} CONTROLVAIVE{'99 modeliD16Y8 6ngin6)Testing, page 11,250
POSITIVE CRANKCASEVENTILATION IPCV) VALVEInspection, page 11-266
AIR CLEANER IACLIReplacement, page 11,244
THROTTLE CABITf nspection/Adjustment. page 1 1,244Installation, page 1 1-245
.iBoov ffetInspection, page 11 247Removal, page 11,248Disassembly, page 1 1-249
POSITIVE CRANKCASEVENTILATION IPCVI VALVEInspection, page 1 1-266
1 1-10
RESONATOR

Probable Cause List lFor th€ DTC Chart, see page 11-971*: '99 - 00 models
Probable GausePageSystem
11 1-107Engine Control Module (ECM)/Powertrain Control Module (l'uM)
PGM-Fl main relay
l^^iti^n cwetam
211-230,231
3't't-237
Section 23
51'1-172,183Crankshaft Position/fop Dead Center/Cylinder Fosltlon sensor clrculr' Lr\F selrsor
circuit
Intake Air Temperature (lAT) sensor circuit
ldle Air Control (lAC) Valve
ldle speed adjustment
Throttle bodY
Throftle cable
Manifold Absolute Pressure (MAP) sensor
Throftle Position (TP) sensor
Barometric pressure (BARO) senso'
Mf g"a, po"ition signal (see page 11-216) or clutch switch signal
Brake switch signal
Air Cleaner
lntake air pipe
Three Way Catalytic Converter (TWC)
Evaporative emission (EVAP) control
Contaminated fuel
ORVR vent shut valvs
't1-124
71 1-194
I11-220 - 223
11-241
'1011-244
1111-115
1211-132
13't1-178
14Section 14. 11-218
1511-210
16't1-244
1811-252
1911-261
20
21*11-296
(cont'd)
11-85

ldle Control System
ldle ControlSystem
lF0505 l Th" """n tool indicates Diagnostic Trouble Code (DTC) PO5O5: tdte controt system malfunction.
NOTE: lf DTC P1508 or P1509 is stored at the same time as DTC P0505, troubleshoot DTC p1508 or p1bog first. thenrecheck for DTC P0505.
Possible Cause
. IAC valve mechanical malfunction
. Throttle body clogged pon, improper adjustment. Intake manifold gasket leakage
. Intake air hose loose leakage
. Vacu um leak
. ECT sensor incorrect output
. Throttle Position sensor incorrect output*r
Troubleshooting Flowchart
The MIL has been reoorted on.DTC P0505 is stored.
Problem verification:1. Start the engine. Hold theeng;ne at 3,000 rpm with noload (jn Park or neutral) untilthe radiator fan comes on, then*r let it idle.t2. with rhe scan toot, ct'eit Ge l
Throttle position should beapprox. 10% with the throttle fully closed.E ngine coolant tempera-ture should be 194 205'F(90 96.Ci.lf they are not within thespec., repair the faulty sen
L._ _9oI9[cr]41 l3. Chec& the engine speed atidle with no-load cond;tionsiheadlights, blower fan, reardefogger, radiator fan, and airconditioner are not operating\see page l1-22O - 223).
Intermittent tailure, system is OKat this time.ls the idle speed OK?
ls it 550 rpm or less?
(To page 11,193)
*1r'96 models only
11-192
(To page ll-193)