98 Honda Civic LX D16y7 Engine Block

8/7/2019 98 Honda Civic LX D16y7 Engine Block

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EngineBlockSpeciafTools .............7-2l l lustratedlndex . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .7-3Flywheel and Drive Plate

Replacement .........7-GConnecting Rod and Crankshaft

EndPlay . . . . . . . . . . . . . . . . .7-6Main BearingsCfearance . . , , , , , , , , , . . . .7-7Selection ................7-8

Connecting Rod Bearings^ Clearance . . . . . . . . . . . . . . .7-B

|J Selection ................7-9Pistons and CrankshaftRemoval . . . . . . . . . . . . . . . . .7-9

Crankshaftfnspect ion . . . . . . . . . . . . . .7-11

Pistonsfnspect ion . , , , , . , , , . . . . ,7-12Installation .............7-20

Cylinder Blocklnspection ..............7-13BoreHoning .. . . . . . . . .7-11

Piston PinsRemoval . . . . . . . . . . . . . . . . .7-14lnstallation .............7-15Inspection ..............7-16

Connecting RodsSeleetion ................7-15

Piston RingsEndGap . . . . . . . . . . . . . . . . .7-17Repfacement .........7-11Ring-to-GrooveClearance...............7-18Alignment ..............7-18

Crankshaft Oil SealInstallation .............7-19

Crankshaftfnstaffation .............7-2O

Oil Panfnstaffation .............7-22

Oil Sealslnstaffation .............7-24


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SpecialTools

Raf.No. Tool Numbor DBcription (Ny I Pag6 Rotorenceo@@@@@oo@@@

07LAB- PV0010007749- 0010000079i17- S80020007948- S80010107973- P80020007973- PE0031007973- PE003200t913 - PE0040007973- S80010007973- 657050007973- 5570600

RingGearHolderDriverSealDriverDriverAttachmentPilotCollarPistonPi nDriverShaftPistonPin Driver HeadPiston Pin BaselnsenPistonBaseHeadPiston BasePistonBaseSpring

11111I11111

7-67-19,257-247- ' t9 ,257-14,157 - 1 4 . 1 5l -14 ,15l - '14 ,157-14,157-'t4,157 - ' t 4 . 1 5

@ o @o

o o

@ @ c,

0

t - 1

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lllustratedlndex

D16Y7engine:I Lrori""t" "t l internalpartswith engineoil duringreassembly.NOTE:. Applyliquidgaskettothematingsurfacesoftherightsidecoverandoi lpumpcasebeforeinstallingthem.. Use liquidgasket.partNo .08718- 0001or 08718- 0003.. Cleanthe oil pa ngasketmatingsurfacesbeforeinstall ingit .

DRAINBOLT44 N. m (4.5 kgf.m, 33 lbf. f t l6 x 1 . Om m12 N. m {1 .2 kgf.m,8 7 lbt 'f t l FLYwHEELcovER

6 x 1 . 0m m12 N. m (1.2 kgt.m, 8. 7 lbt. f t)o[ rlt cnsrer \,::::T: I \Hii,ilJ"i'.'' \ 'y"y"::::-I $5./

OIL PANRefetto page7-22wheninstall ing.

ffi::: I fR..r'.*"'" I gNliJ'J.f-->


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lllustrated Index(cont'dlI rubricateal t internalpartswith engineoil duringreassembly.NOTE:. Apply l iquidgaskettothematingsurfacesofthe rightsidecoveran doi l pumpcasebeforeinstall ingthem.! Us eliquidgasket,pa n No. 08718- 0001or 08718- 0003.. Cleanthe oil pan gasketmatingsurfacesbeforeinstall ingit .D16Y5.Dl6Y8 engin"", DnAtNBoL,39 N. m14.0kgf'm,

WASHER OII.PANRelerto page7-23wheninstall ing.Apply liquidgaskertothesepotnts,29 tbf.f!) \ \ \,-,6 r 1 . o m m \ %12 N . m (1 . 2 kgf 'm,8.7 lbf. tr l

FLYWHEELCOVERIM/T)1 2 x 1 . 0m m1 1 8N . m(12.Okst.m, 87 lbl. f t l

1 1 x1 . 5m m51 N.m15.2kgt m, 38 lbf.{t)Applyengineoilto the boltthreads.NOTE:Aftertorquingeachcap,turn crankshaftto checklor binding.

\sFLYWHEELIM/TI

OIL PAN GASKETReplace.MAINBEARING

MAIN BEARINGSSelection,page7- 8NOTE:New mainbearingsmustbe selectedby matchingcrank

6 x 1.0 mrn11 N.m {1.1 kgt .m,8 lb f . f r l

DRIVEPLATECOVERlA/Tor CVTI1 2 x 1 . Om m74 N.m(7.5 kgf.m, 54 lbf. f t)

DRIVEPLAYE(A/Tor CVTICheckfor cracks.

OIL SCREENGASKETReplace.

pages7-19an d7-25Replace.RIGHT SIDE COVERApply l iquidgasketto matingsurface.

6 x 1 . 0 m m11 N. m 11 . 1kgt .m,8 tbf.frl

DOWELPIN

CRANKSHAFTOILSEAL

OIL PUMPOverhaul,page I 9Removal/ lnspection,page 8-10Applyliquidgasketto mating surface. THRUSTWASHERSGroovedsidesface outward.NOTE:Thrustwasherthicknessis f ixed and must no t be changedby grindingor shimming.

CRANKSHAFTSEALInstallat ion,pages7-24and8-11Feplace.DOWEL PIN BREATHINGPORTCOVERMOUNT BOLTS6 x 1 . 0m m11 N.m {1.1 kgf.m, 8 lbf. fr lApply l iquidgaskettothe bolt threads.6 x

'1.0 mm'11N.m 11.1 kgf .m,I lbt.fr)

7-4

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NOTE:New rod bearingsmust be selectedby matchingconneclingro d assemblyand crankshaftidentif icationmarkin(seepage7-9).Lubricateall internal parts with engine oil duringreassemblv.

PISTONINSTALLATIONDIRECTION:EXHAUST

4\A6\/Al o o l t . - l . t lv\y\7vINTAKE

tl,^t , PISTON RINGSw,* a l@ ) olisnment,pase7-18

PISTONInspection,page7-12NOTE: Beloreremoving piston,inspectthetop of the cylinderborefor carbonbuild,uporridge. Removeridge il necessary,page7-'10

PISTONPINRemoval,page7-14Installat ion,page7-15hspection,page7-16

CONNECTINGRODEnd play, page7-6Selection,page 7-15

CONNECNNGRODBEARINGS

ENGINEBLOCKCylinderboreinspection,page7-13Warpageinspection,page7-'13Cylinderborehoning,page7'14

Inspecttop of eachcylinderborefor c6rbonbuild-upor r idgebeforeremoving piston.Removeridge if necessary,page7-'10

CONNECNNGRODCAPNUT8 x 0,75mm31Nm(3,2kgf .m,23 tbt.ft)Applyengineoil toth eboltthreads.NOTE:After torquing eachbearingcap,rotatecrankshafttochecktor binding.

Clearance.page7-8Selection,page7-9

CONNECTINGROOBEARINGlnstallat ion.page7-20NOTE: Installcapsso thebearingrecessis on thesame side as the recessin the rod.

7-


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GonnectingRodandFlywheeland Drive Plate CrankshaftReplacementManual Transmission:Removeth e six flywheel bolts, then separateth e fly-whee l f rom the crankshaf tf l ange.Af te r ins ta l la t ion ,tightenthe boltsin a crisscrosspattern.

RINGGEARHOLDER07LAB- PV00100--4T-1 Htr

ENGINEBLOCKRINGGEARInspectringgearteeth for wear ordamage.12 x 1.0mm118N,m 112.0kgtm,87 lbl.ftl

RINGGEARHOLDER07LAB- PV(x'l00

Automatic Transmission:Removethe six driveplatebolts,then separateth e driveplatefrom the crankshaftf lange.After installation,tight-en the boltsin a crisscrossoattern.

12x 1 . 0mm

7-674 N.m{7.5kgf m,54lblf t l

EndPlayConnGtingRod End Play:Standard(New):0.15- 0.30mm {0.006- 0.012in lServiceLimit: 0.,[|)mm {0.016inl

. l l out-of-tolerance,installa new connectingrod.. lf sti l l out-of-tolerance.replacethe crankshaft(seepages7- 9an d7-20).Pushthe crankshaftf irmly away from the disl indicator,and zeroth e dial againstthe end of the crankshaft.Thenpull the crankshaftf irmly backtowardthe indicator;dialreadingshouldno t exceedservicelimit.

CrankshaftEnd Play:Stsndard{Nw):0.10- 0.35 mm {0.004- 0.0lit in}ServicELimit: 0.45 mm (0.018inl. lf en d play is excessive,inspectthe thrust wsshersand thrustsurfaceon the crankshaft.Replacepansas necessary.NOTE:Thrustwasherthicknessis fixedand mustnot bechangedeitherby grindingor shimming.Thrustwashersare installedwith groovedsidesfacingoutward.


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Main BearingsClearance1 . To checkmain bear ing- to - journa lo i l c learance,removeth e maincapsand bearinghalves.

C leaneachmain journa land bear ingha l t w i th acleanshoptowel.Piaceon estrip of plastigageacrosseachmainjour-na l .NOTE:tt the engineis sti l l in the carwhenyou boltth e main cap down to checkclearance,th e weightof the crankshaftand flywheelwill f lattenth e plasti-gage further than just the torque on the cap bolt,an d give you an incorrectreading.For an accurateread ing ,suppor tthe crankwi th a jack underthecounterwe igh tsand checkon ly one bear ingat atime.Re ins ta l lthe bear ingsand caps,then to rquethebolts.lst step: 25 N.m 12.5kgf'm, 18 lbf'ft)Final step: 51 N'm 15.2kgl.m, 38 lbf'ft)NOTE:Do not rotatethe crankshaftduring inspec-tton.Removethe cap and bearingagain.and measurethe widestpa d of the Plastigage.Main Bearing-to-JournalOil Clearance:StandardlNew):No . 1, 5 Journals:0.018- 0.036mm (0.0007- 0'001,+inlNo- 2, 3, i[ Jou]nals:0.02/t- 0.0,[2mm {0.0009- 0.0017in)SsrviceLimit: 0-05mm {0.002inl

7 .

lf the plastigagemeasuresto o wide or too narrow(removeth e engineif it 's sti l l in the carl.removethcrankshaft,an d removeth e upperhalf ol the beaing. Installa new, completebearingwith the samcolor code (selectthe color as shown on th e nepage),and recheckth eclearance.CAUTION: Do not file, shim, or sqape the bearingor the capsto adiust clearance.It the plastigageshowsthe clearanceis sti l l incorect,try the next largeror smallerbearing(thecololistedaboveor belowthatone),and checkagain.NOTE:lf the oroperclearancecannot be obtainby usingthe appropriatelargeror smallerbearingreplacethe crankshaftan dstartover.


8/25

MainBearings ConnectingRodBearingsSelectionCAUTION: lf the codes are indeciDherablebecauseof anaccumulationot dirt and dust, do not scrub them with awire brush or scraper.Cleanthem only with solvent ordetergent.CrankshaftBoreCodeLocationLettershavebeenstampedon the end of the blockas acodefor the sizeof eachof the 5 mainjournalbores.Use them, and th e numbersstamDedon the crankshaft(codesfo r mainjournalsizel,to choosethe correctbear-inos.

Main Joulnal CodeLocation(Numbers)

Bearing ldentificationColorcodeison theedge ofthe bearing.

-8

I f-i--l Il l - - J lt l . . - lt t 3 t l+ t n t +Smaller Smallermain bearingjourn8l (thicker)

B c Dcrankoore

Smallerbearing{thicker)Red Pink G.een

Gren BrownGreen Black

Green Brown Elack Blue

Clearance1, Removethe connectingrod capand bearinghalf.2 . C leanthe crankshaf trod journa land bear ingha l fwith a cleanshoptowel.3. Placea stripof plastigageacrossthe rodjournal.4 . Re ins ta l lt he bear ingha l fandcap,andtorquethenuts .

Torque31 N.m (3.2kgf.m. 23 lbf.ftlNOTE:Do not rotatethe crankshaftduring inspec-t ton .Removethe rod cap and bearinghalf,and measurethe widestpartof the plastigage.ConnctingRod Eearing-to-JouJnalOil Clearance:StandardlNewl:0.020- 0.038mm(0.0008- 0.0015in )ServiceLimit: 0.05 mm (0.(X)2in)

lf the plastigagemeasuresto o wide or too narrow,removethe upperhalfof the bearing,installa new,completebearingwith the s ame color code (selectth e color as shown on the next page),and recheckthe clearance.CAUTION:Do not l i le, shim.or scrapethe boaringsor the capsto adiust clearance.lf th e plastigageshowsthe clearanceis sti l l incor-rect,try the next largeror smallerbearing(thecolorl i s tedaboveor be lowthat one) ,and checkc lear -anceaga in .NOTE;lf the prooerclearancecannotbe obtainedby usingth e appropriatelargeror smallerbearings,replacethe crankshaftand stan over.

t

7 .

PLASTIGAGESTRIP

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PistonsandCrankshaftSelectionCAUTION:lf the codes are indecipherablebecauseofan accumulationol dirt and dust, do not scrub themwith a wire brush or scraper,Cleanthem only with sol-vgnt or detorgent.ConnectingRodCodeLocationNumbershave beenstampedon the side of eachcon-nectingrod as a code for the sizeof the big end. Usethem, and the lettersstampedon the crankshaft(codesfo r rod journalsize),to choosethe correctbearlngs.

Baring ldentif icationColorcodeis on the Larger big end boreedge ofthe bearing. 2 3 4Smallerbearing{thicker)

I F;. ' l Il l B o r l l l ll l . - . - - - - - - . l lI I C o r l l l | |l - lI l D o , r r r rl +

Smaller Smallerrod bearingiournal (thicker)

Halfof the numberisstampedon bearingca pan dthe otherhall is stampedon th erod.

connecting Rod Journal code Locations lLettersl

Re d Pink GreenPink Green Erown

Green Brown BlackGren Brown Black Blue

7

RemovalRemovethe oil pa nassembly.Removeth e right sidecover.

1 .

RIGHTSIDECOVER

OIL SCREEN

O-RINGRePlace4. Remove the oil pump.


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PistonsandCrankshaftRemoval(cont'dl5. Removethe boltsand the bearingcap.

CAUTION: To prev6nt warpago, unscrew the bohsin soquencel/3 turn at a tims; rgpoatthe sequencountil 8ll bolts ara loosonsd.

MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE

Removethe rod caps/bearingsand maincaps/bear-ings.Keepall caps/bearingsin orderLift the crankshaftout of the engine,being carefulnot to damagejournals.

7-10

7.

CRANKSHAFT

'10.

Removethe upper bearing halvesfrom the connect-ing rodsand set them asidewith their respectivecaps.Reinstallthe main capsand bearingson the engineIn properorder.lf yo u ca nfeela ridgeof metalor hardcarbonaroundthe top o f eachcy l inder ,removei t w i th a r idgereamer.Followthe reamermanufacturer'sinstruc-tions.CAUTION: lf the ridgo is not removed,it may dam-age tho plstonsas they arepushedout.

Use the woode n handleof a hammerto drive thepistonsout.

Reinstallthe connectingrod bearingsan dcapsafterremovingeachpiston/connectingrod assembly.Mark eachpiston/connectingro d assemblywith itscylindernumberto avoidmixupon reassembly.NOTE:The existingnumberon the connectingro ddoes not indicateit s posit ionin the engine,it indi-catesthe rod bore size.

't1.

12 .

13 .

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11/25

GrankshaftInspection. Cleanthe crankshaftoil passageswith pipecleanersor a suitablebrush.. Checkthe keywavand threads.Alignmont

. Measurerunouton a l l ma in iourna lsto makesurethe crankis not bent.

. The differencebetweenmeasurementson eachjournalmust not be morethanthe servicelimit.CrankshaftTotal IndicatadRunout:Standard{Nowl: 0.03 mm 10.001in} max.SorviceLimh: 0.04mm 10.002in)

DIAL INOICATORRotate lwo completerevolut ions.

Suppon with lathelype tool or V-blocks.

Out-of-Roundand Tapel. Measureout-o{-roundat the middle of each roan dmainjournalin tw o places.. The differencebetweenmeasurementson eacjournalmust not be morethanthe servicelimit,Journal Out-ot-Round:Standard(Now):0.0025mm (0.0001inl max.ServiceLimit: 0.005mm (0.0002inl

roundat midd

MeasurelaPerat edges.

. Measuretaper at edges of each rod and maijourna l .

. The differencebetlveenmeasurementson eacjournalmust not be morethan the servicelimit.JournalTaper:Standard{Newl:0.0025mm (0.0001in) max.ServiceLimit: 0.005mm 10.0002in)

7 - 1


12/25

PistonsInspection1 .

2 .

Checkth e pistonfor distortionor cracks.NOTE:l f cylinderis bored,an oversizedpistonmustbe used.Measurep is tond iametera t d is tanceA t rom thebottom of the skirt.A: 5 mm (0.2in )PistonDiameter:Standard(Nw):74.990- 74.990mm12.9520- 2.952itinlServiceLimh: 7i1.970mm {2.9516in}

SKIRTDIAMETER

3. Calculatethe difference betweenthe cvlinder borediameter(seepage7-131and pistondiameter.Piston-to-CylindrClearancaStandsrd{New): 0.010- 0.0i|()mm(0.000'l- 0.0016inlServiceLimit: 0.05 mm {0.002inl

lf the clearanceis nearor exceedsthe servicelimit,inspectth e pistonand cvlinderblockfo r excessivewear.OversizPistonDismatel0.25175.23-75.21mn (2.9618- 2.9622inl0.50:75.48- 75.49mm 12.9716- 2.9720in)


13/25

CylinderBlockInspection'1. Measurewear and taDerin directionsX and Y at th reelevelsin eachcvlinderas shown.

CylinderBore SizeStandard{New):75.00- 75.02mm(2.953- 2.95,1in)SrvicoLimit: 75.07mm {2.955inlOvsFizeO.25t75.25- 75.27mm (2.9626- 2.963,[in]0.50:75.50- 75.52mm 12.9721-2.9732in1Bore TaperLimit (Differencebetwoen tirst and third measure.m6nt) 0.05mm (0.002in)

7-1

. lf measurementsin any cylinderare beyondth eOversizeBoreServiceLimit,replacethe block.

. lf the block is to be rebored.referto PistonCleaanceInspection(seepage7 12)afterreboring.

NOTE;Scoredor scratchedcylinderboresmust behoned.ReboringLimit: 0.50 mm (0.020in)

2. Checkthe top of the blockfor warpage.Measurealong the edge sand acrossthe centerasshown.

SURFACESTO 8E MEASURED

Engine Block Warpage:Standard(New):0.07mm (0.003in) max.ServiceLimit: 0.10 mm 10.004in)PRECISIONSTRAIGHTEDGE


14/25

GylinderBlock Piston Pins

l .BoreHoning

Measurecylinderboresas shownon page7-13.lf th eblockis to be reused,honethe cylindersan d remea-surethe bores.Honecylinderboreswith honingoil and a fine (400grit)stonein a 60 dagreecross-hatchpattern.NOTEi. Useonly a rigid honewith 400grit or t iner stonesuchas Sunnen,Ammco,or equivalent.. Do not us estonesthat areworn or broken.

When hon ing i s comple te .thorough lyc leantheengineblockof all metalparticles.Washthe cylin-der bores with hot soapy water, then dry and oilimmediatelyto preventrusting.NOTE:Neverus esolvent,it wil l only redistributeth egrit on the cylinderwalls.lf scoringor scratchesare sti l l presentin cylinderbores after honing to the servicelimit. reboreth ecylinderblock,NOTE:Somelightverticalscoringand scratchingisacceptableif it is not deepenoughto catchyour fin-gernailand doesnot runthe full lengthof the bore.

CYLINDERBLOCKCYLINDERHONE

NOTE:. After honing,cleanthe cylinderthoroughlywithsoapy waler.. Onlya scoredor scratchedcylinderboremust benoned.

7-14

Removal1. Assemble the specialtool as shown.

PISTONBASEHEAD07973- SB00100

2. Assembleand adjust the length of the pistondriverand shaftto 53 mm (2.1in) as shown.PISTONPINDRIVERHEAD07973- PE00320Pres3

f tPISTONPINBASEINSERT07973- PE00a00

gE .g \Y .,rro")". rr*,"o079?3- 657060053 mm(21 in)

NOTE|Us ea hydraulicpress.Whenpressingth e pi n in or out,makesure that the recessedponionofthe pistonalignswith the l ipson the collar.Placeth e pistonon the specialtool and pressth epi n ou t with the specialtoolsand a hydraulicpress.

p t n

+PISTONPINDRIVERSHAFT0?973- PE00310PILOTOOLLAR07973- PE00200


15/25

GonnectingRods PistonPinsSeleetionEachrod falls into one of four toleranceranges(from0 to+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in )incrementsldependingon the sizeof it s big end bore.lt 'sthen stampedwith a number11 ,2, 3, or 4l indicatingtheran9e.You may l ind any combinat iono l 1 ,2 ,3 , o r 4 in anyengine.Normal Bore Size:,18.0mm (1.89inlNOTE:ReferencenumbeGar efo r big end bore sizeand doNO Tindicatoth e positionof the rod in the engine,Inspectconnectingrod for cracksand heatdamage.

Installation1. Us ea hvdraulicDressfor installation.

a When pressingthe pin in or out, be sureyou posi-tion the rscessedflat on the pistonagainstthe lugson the baseattachment,

The arrow must face thetiming belt sideol th eengineand the connectingrod oil hole must face therear of the

PISTOI{P|r{DRIVERHEAD07973- PEOO320

Adjust the length of thepiston pin driver to53 mm (2.09in)

PISTO PII{ DRIVERSHAFT07973-PE00310

ffi--Z PFroI{PPILOTCOTLAR07973- PEq)200PISTOI{PINBASEI SERT07973 - PCOO400

PISTOI{BASEHEAD07973 - SB(xtl (xt

7-1


16/25

PistonPinsInspection'1 . Measurethe diameterot th e pistonpin.

Piston Pin Diamcter:Standard(New):18.994- 19.000mmOveIsiz: (0.7,078- 0.7{80 inl18.997- 19.003{0.7,u9- 0.7,181in)NOTE:All replacementpistonpinsar eoversize.

2. Zerothe dial indicatorto the pistonpi n diameter.

7-16

\3. Measureth e pistonpin-to-pistonclearance.

NOTE:Checkth e pistonfor distortionor cracks.lf the pistonpi n clearanceis greaterthan 0.024mm(0.0009in) , remeasureus ingan overs izedp is tonp in .Piston Pin-to-PistonClsarance:Standard{Newl: 0.010- 0.022mm{0.0004- 0.0009inl

Checkthe differencebetweenth e pistonpi n diame-ter andthe connectingrod smallend diameter,Piston Pin-to-ConnectingRod Intrferonc:Standard(New):0.014- 0.040mm10.0006- 0.0016inl


17/25

PistonRings1 .EndGap

Using a piston, push a new ring into the cylinderbore15- 20 mm (0.6- 0. 8in )trom the bottom.Measureth e pistonringend-gapwith a feelergauge:. lf the ga p is too small,checkto see if you haveth e properringsfo r your engine.. lf the ga p is to o large,recheckth e cylinderborediameteragainstthe wear l imitson page7-13.lf the bore is over the servicelimit. the cvlinderblockmustbe rebored.Piston RingEnd-Gap:Top RingSt8ndardlNswl:0.15- 0.30mm{0.006- 0.012in )ServiceLimit: 0.60 mm 10.024inlSecondRingStandardlN6wl: 0.30- 0.,l5mm{0.012- 0.018in lServiceLimit: 0.70 mm (0.028inlOil RingStandardlNewl: 0.20- 0.70 mm{0.008- 0.028inlSorviceLimit: 0.80 mm (0.031in)

15-20 m m{0.6-O.8 in l

Replacement2 .1 . Usinga rin g expander,removethe old pistonrings

Cleanall ringgroovesthoroughly.NOTE:. Use a squared 'o f fb rokenr ing or r ing groovcleanerwith bladeto fit pistongrooves.. Top ringgrooveis 1.0mm (0.039in )wide.. Secondringgrooveis 1.2mm (0.047in) wide.. O i l r inggrooveis2 .8mm (0.1 Iin )w ide .. Filedown the bladeif necessary.CAUTION:Do not uso a wire brush to clean ringlands,or cut ring landsdoeperwith cleaningtool.NOTE:lf th e pistonis to be separatedfrom the connectingrod,do not installnew ringsyet.Installnew rings in th e propersequencean d position {seepage7-18).NOTE:Do not reuseol d pistonrings.

RINGEXPANDER{Commerciallyavailable)

7 - 1


18/25

PistonRingsRing-to-GrooveClearanceAfter install inga new set of rings,measurethe ring-to-grooveclearances:Top Ring ClearanceStandard lNew): 0.035- 0.060mm{0.0014- 0.0024in}Servic. Limit: 0.13mm (0.005inlSecondRing ClearanceStandard(Now):0.030- 0.055mm(0.0012- 0.0022io)ServiceLimit: 0.13 mm 10.005inl

7-18

Alignment1, Installth e ringsas shown.

PistonRing Dimensions:r-T- fI l r 'I I '| . - !A

Top Ring (Standatd):A: 2. 6mm {0.10in }B: 1.0mm (0.0/tin )SecondRing {Standard):A: 3.0mm (0.12in lB: 1.2mm (0.05in lNOTE:Th e manufacturingmarks must be facingupward.

,orrrno--"-@SECONORING.>

TOPBINGlchromo)


19/25

CrankshaftOil Seal

2. Rotatethe rings in theirgroovesto makesuretheydo no t bind.Positionthe ring end gapsas shown

SECONDRINGGAP

Approx.90"

TOP RINGGAP

DO NO Tposit ionan yrrngga pat pistonthrustsurfaces,

DO NOTposit ionsn y ringga Pin l inewith the pistonpi n hole. OILRINGGAP

lnstallationTh esealsurfaceon the blockshouldbe dry.Applya lightcoatof oil to th ecrankshaftan dtothe lio of the seal.

Drivethe crankshaftoil sealintothe rightsidecoveusingthe specialtools.NOTE:Drivethe crankshaftoil sealin squarely.

DRIVER07749- 0010000

1 .

Installsealwith th epart numbersidefacingoui.

Confirmequalclearanceall the way aroundwith afeelergauge.Clearance:0. 5- 0.8mm {0.02- 0.03in l

NOTE:Referto pages'I-24and 8-11for installatioof the oi l oumo sidecrankshaftoil seal.

0 . 5-0 . 8 mm10.02-O.03in )

7-1


20/25

Crankshaftlnstallation

Beforeinstall ingth e pistons,applya coatofengineoil to the ringgroovesand cylinderbores.l f the crankshaft is already installed:. Set the crankshaftto BDCfor eachcylinder.. Removeth e connectingrod caps.an d slip shortsectionsof rubberhose over the threadedendsof the connectingrod bolts.. Installth e ring compressor,checkthat the bearing is securelyin place,then positionth e pistonin the cy l inder .and tap i t i s us ingthe woodenhand leo f a hammer .. Stop after the ring compressorpops free, andcheckthe connectingrod-to-crankjournalalign-ment beforepushingth e pistonintoplace.. Installth e rod capswith bearings,and torqueth enutsto :

31 N.m13.2ksl.m,23lbf.t i)Apply engineoi l to the boltthreads.lf the crankshaftis not installed:. Removethe rod capsand bear ings,ins ta l lt hering compressor,then positionth e pistonin thecylinderandta p it in usingthe woodenhandleofa hammer .. Positional l Distonsat top deadcenter.

1 .

2.

RUBEERNOTE:Maintaindownwardforce on the ring com-pressorto preventr ingsf rom expand ingbeforeenteringthe cylinderbore.RING

The arrow must facethe t iming belt sideo f t he eng jne .

\ '

COMPRESSOR(Commerciallyavailable)

7-20

rod

lnstallationBetoreinstall ingthe crankshaft,applya coatotengineoil to the mainbearingsand rod bear-ings,

Installthe thrustwashersin th e No. 4 journalof thecylinderblock.Insertbearinghalvesin the cylinderblockand con-nectingrods.Holdthe crankshaftso the rodjournalsfor cylindersNo. 2 and No.3 arestraightdown.Lowerth e crankshaftinto the blo ck,seatingthe rodjourna lsin to connect ingrods No,2 , No.3 . Ins ta l lth e ro dcapsand nutsfinger-tight.

\

1 .

THRUST WASHERSGroovedsidestace LRotatethe crankshaftclockwise.seatjournals intoconnectingrodsNo . 1 an d No.4. lnstallth e rod capsan dnutsfinger-tight.NOTE:Installthe capsso the bearingrecessis onthe samesideas the recessin the rod.Checkrod bearingclearancewith plastigage(seepage7-8).thentorquethe capnuts.Torque:31 N.m (3.2kgf.m,23 lbf,ft)Applyengineoil to the bolt threads.NOTE:Referencenumberson the connectingro dare for big-endbore toleranceand do not indicateth e positionof the pistonin the engine.

Lineup the markswheninstall ingth econnectingcap.

l - rrn-)- ---1l t--l-'--tllf -ll t l l


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7. Installthemainbearingcaps.Checkclearanceswith plastigage(see page 7-7),thentightenthe bearingcap boltsin 2 steps.Fi6t st6p: 25 N'm (2.5kgf'm. 18 lbt.ft)Secondstsp: 5t N.m (5.2kgf.m,38 lbf,ft)NOTE: Coat the thrust washer surfacesand boltthresdswith oil.MAN BEAHNG CAP BOLTSTIGHTENINGSEOUENCE

CAUTION: Whenever any crankshaft bearing orconnecting rod bgajing is rgplacad,it is neces3aryaft6r roassemblyto run the ongino at idling spooduntil it reachesnormal operatingtemperalure, thoncontinuo to run it for approximalely 15 minutes.

8. Apply l iquid gasketto the block mating surfaceothe right side cover,then install it on the cylindeblock.NOTE:. Us eliquidgasket,partNo. 08718- 0001or 0871- 0003.. Checkthat the matingsurfacesar ecleanand drbeforeapplyingliquidgasket. Apply l iquidgasketevenly,b6ingcarefultocoveallthe matingsurface.. To preventoil leakage.apply l iquidgasketto thinnerthreadsof the bolt holes.. Do not installth e parts if f ive minutesor morhaveelapsedsinceapplyingthe liquidgasket,Insteadreapplyliquidgasketafter removingthold residue,. After assemblv,wait at least30 minutesbefor

fi l l ingthe enginewith oil.

RIGHTSIDECO

kgl.m

(cont'd

7-2

6 x 1 . 0m m1 1 N . m{ 1 . 18 tbt.f t lDOWELPIN


22/25

Crankshaft Oil PanInstallation(cont'd)9. Apply l iquidgasketto the oil pump matingsurfaceof the b lock ,thenins ta l lt he o i l pumpon the cy l in -der block.

Applygreaseto the lipsof the oil seals.Then,ins ta l lt he o i l pumpwhi lea l ign ingthe innerro tor w i th the crankshaf t .When the pump is inplace,clean any excessgreaseoff the crankshaft,thencheckthat the oi l seall ipsare notdistorted.

NOTE:. Apply a l ightcoat of oil to the crankshaftand tothe l ipo f thesea l .. Use new O-r ingsand app lyo i l when ins ta l l i ngthem.10. Ins ta l lt heo i l pumpandoi l screen.6 x 1 . 0m m11 N . m {1 . 1kgf .m,a tbt.{t}6 x 1 . 0 m m

DOWELPIN

6 x 1 . 0m m1 1 N . m{'l.1 kgl.m, 8 lbf, lt}

OII-SCREEN

DOWELPI NO-RINGReplace.

., ,.t ,.i

r -zz

Apply laquidgasketalongthe broken

OIL PUMPHOUSING

11N. m{1.1kgf.m,

InstallationO16Y7enginc:1. Apply l iquid gasketon the oil pump an d right sidecovermatingareasas shownbelow.

NOTE:. Us eliquidgasket,partNo.08718- 0001or 08718- 0003.. Checkthatthe matingsurfacesare cleanand drybeforeapplyingliquidgasket.. Apply l iquid gasketas an even bead.centeredbetweenthe edgesof the matingsurface.. lo preventoi l leakage,applyliquidgasketto theinnerthreadsof the bolt holes.. Do not installth e parts if f ive minutesor morehavee lapseds inceapp ly ingthe l i qu idgasket .Insteadreapplyliquid gasketafter removingth eold residue.. After assembly,wait at least30 minutesbeforefi l l ingth e enginewith oil.

CYLINOERBr_ocK

L

App ly l iqu id gasketto these pornts,

Apply liquid gasketto these pornts.


23/25

2. Ins ta l ltheo i l pangasketando i lpan.NOTE:. Us ea ne woi l pa ngasket.. Installthe oil pa nno morethan five minutesafterapplyingliquidgasket.

OI LPA N

Apply l iquidgaskettothesepoants.

PANGASKETReplace.to thesepoints.3. Tightenthe bolts andas shownbelow. nutsf ingert igh ta t s i x po in ts

Tightenall boltsan dnuts,startingfrom boltO, clock-wisein threesteps.NOTE:Excessivetighteningcan causedistonionofoil pa ngasketand oil leakage.Torque:12 N.m(1.2kgl.m,8.7lbt.ft)

D16Y5,D16Y8engines:1 . Ins ta l ltheo i l pangasketontheo i l pan.

NOTE:. Us eliquidgasket,partNo .08718- 0001or 0871, 0003.. Checkthat the matingsurfacesar ecleanand drybeforeapplyingliquidgasket.o App ly l i qu idgasketas an evenbead.centerebetweenthe edgesof the matingsurface.. To preventoil leakageapply l iquidgasketto theinnerthreadsof the bolt holes.. Do not installth e parts if f ive minutesor morehaveelapsedsinceapplyingthe liquidgasket.Instead,reapplyliquidgasketafterremovingth eold residue.. After assembly,wait at least30 minutesbeforfi l l ingthe enginewith oil.

OIL PANGASKETReplace.

(cont'd

7-2

OI LPA N


24/25

OilPan Oil SealsInstallation(cont'd)2. Apply l iquid gasketto the block mating surfaces,then ins ta l lthe o i l pan.App ly l i qu idgasketto theshadedareas.

3. Tighten the nuts f inger{ight at six points as shown

o

4. Tightenall boltsan dnuts,startingfrom nu tO, clock-wisein threesteps.NOTErExcessivetighteningcan causedistortionofoi l pan gasketand oil leakage.Torque:12 N.m(1.2kgf'm,8.7lbl.ft)

oa

t -z+

OIL PAN

InstallationNOTE:. Engineremovalis not required.. Th ecrankshaftoil sealhousingshouldbe dry.Apply a l ight coat of greaseto the crankshaftand tothe lipsof the seals.1. Usingthe specialtool,drivein the timing pulley-endsealuntilthe driverbottomsagainstthe oil pump.When the seal is in place,cleanany excessgreaseof f the crankshaftand checkthat the oil seal l ip isnot distorted.

L07947-SB00200lnstallsealwith th epart number sidefacingout.


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2. Measurethe flywheel-endsealthicknessand the oilsealhousingdepth.Usingthe specialtool. driveth eflywheel-endseal into the rear cover to the pointwherethe clearancebetweenthe boftom of the oilsealand the rightsidecoveris 0.5- 0. 8mm (0.02-0.03in ) (seepage7-191.NOTE:Align the hole in the driverattachmentwithth e pi n on the crankshaft.

07749-0010000

DRIVERATTACHMENT07948-S800101lnstallsealwathth epartnumbersidefacingout.

Documents

98 Honda Civic LX D16y7 Engine Block