Honda Civic/Del Sol 1996-2000

Rocker Arms/Shafts

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REMOVAL & INSTALLATION



The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.

1.6L (D16Y5) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the ignition wires. Remove the spark plugs and note their cylinder assignments.
  4.  
  5. Remove the valve cover.
  6.  
  7. Rotate the crankshaft to set the No. 1 cylinder to Top Dead Center (TDC) for the compression stroke. The white TDC mark on the crankshaft pulley aligns with the pointers on the lower timing cover.
  8.  
  9. Remove the distributor.
  10.  
  11. Loosen the valve adjusting screws.
  12.  
  13. Label and disconnect the VTEC solenoid valve connector.
  14.  
  15. Loosen the camshaft holder bolts two turns at a time in a crisscross pattern to prevent damaging the valves or rocker assembly.
  16.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt loosening sequence-1.6L (D16Y5) engine

  1. Remove the rocker arm and shaft assemblies together with the camshaft holders. Do not remove the rocker shaft bolts yet. The bolts keep the bearing caps, springs, and rocker arms in place on the shafts.
  2.  

The rocker arms and shafts are an assembly; they must be removed from the engine as a unit. Always follow the torque sequence carefully when installing the rocker shaft assembly.

  1. Remove the camshaft holder bolts from the rocker arm and shaft assembly.
  2.  
  3. Bundle the intake rocker arm assemblies with rubber bands so they don't separate when the intake rocker shaft is removed.
  4.  
  5. Disassemble the rocker arm and shaft assemblies. Label the parts as they are removed from the shafts to ensure reinstallation in the original location.
  6.  
  7. Disassemble the rocker arm assemblies taking care not to mix up any of the parts. Inspect the rocker arm synchronizing and timing pistons by pushing them with your fingers. If the pistons don't move smoothly in the rocker arm bores, replace the rocker arm assembly.
  8.  
  9. Apply oil to the synchronizing pistons, timing piston, and timing spring and reassemble the rocker arms. Bundle the rocker arm assemblies with rubber bands to prevent the parts from separating.
  10.  
  11. Inspect the timing plates and return springs which are located on the camshaft holders. Set each timing plate and return spring so that the C-shaped upper arm of the plate is position parallel to the top of the camshaft holder.
  12.  

To install:

  1. Verify that the engine is set at TDC/compression for the No. 1 cylinder.
  2.  
  3. Lubricate the camshaft journals and lobes. Coat the rocker shafts and camshaft holders with oil.
  4.  
  5. Remove the oil control orifice. Thoroughly clean it and reinstall it with a new O-ring.
  6.  
  7. Install a new camshaft seal if necessary.
  8.  
  9. Assemble the rocker arm and shaft assemblies. Be sure the intake shaft collars and exhaust shaft springs are in the proper locations.
  10.  
  11. After the rocker arms and shafts are assembled, cut the rubber bands and remove them from the intake rockers. Be sure that no rubber band fragments are left in the engine.
  12.  
  13. Apply fresh oil to the threads of camshaft holder bolts, then install them.
  14.  
  15. Apply liquid gasket to the cylinder head mating surfaces of the No. 1 and No. 5 camshaft holders. Do not allow the sealant to cure before installation.
  16.  
  17. Set the rocker arm and shaft assembly in place. Install and hand-tighten the bolts. Tighten each bolt two turns at a time in the crisscross sequence so that the rockers are evenly tightened and don't bind on the valves. Tighten the 8mm rocker arm bolts to 14 ft. lbs. (20 Nm). Tighten the 6mm bolts to 9 ft. lbs. (12 Nm).
  18.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt torque sequence-1.6L (D16Y5) engine

  1. Starting with the No. 1 cylinder at TDC/compression, adjust the valve clearances. After the clearance has been reached, tighten the locknuts to 14 ft. lbs. (20 Nm). Set the No. 3, No. 4, and No. 2 cylinders at TDC/compression, and adjust their valve clearances.

    Intake: 0.007-0.009 in. (0.18-0.22mm)
     
    Exhaust: 0.009-0.011 in. (0.23-0.27mm)
     

  2.  
  3. Remove the VTEC solenoid valve, then remove the filter. Install a new VTEC solenoid valve filter. Tighten the solenoid valve bolts to 9 ft. lbs. (12 Nm) and reconnect the solenoid valve connector.
  4.  
  5. Rotate the crankshaft to set the No. 1 cylinder at TDC/compression. Then, manually inspect the operation of each of the VTEC intake rocker arms:
    1. Move the No. 1 cylinder's secondary intake rocker arm up and down.
    2.  
    3. Verify that the secondary intake rocker arm moves independently of the primary intake rocker arm.
    4.  
    5. Repeat the rocker arm inspection for the other three cylinders with each cylinder set at TDC/compression.
    6.  

  6.  



Click image to see an enlarged view

Fig. VTEC rocker arm inspection-1.6L (D16Y5) engine

  1. Rotate the crankshaft back to TDC/compression for the No. 1 cylinder. Install the distributor, but do not tighten the mounting bolts yet.
  2.  
  3. Tighten the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
  4.  
  5. Install the valve cover. Be sure the gasket is in good condition, and apply sealant to the corners where the gasket meets the camshaft holders.
  6.  
  7. Install the spark plugs and reconnect the ignition wires.
  8.  
  9. Drain the engine oil and remove the oil filter. Install a new oil filter and refill the engine with fresh oil.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Warm the engine up to normal operating temperature.
  14.  
  15. Check the ignition timing and adjust it if necessary. Then, tighten the distributor mounting bolts to 17 ft. lbs. (24 Nm).
  16.  
  17. Check all fluid levels. Test drive the vehicle and observe the engine RPM changes at various speeds.
  18.  

1.6L (D16Y7) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the ignition wires. Remove the spark plugs and note their cylinder assignments.
  4.  
  5. Remove the valve cover and the upper timing belt cover.
  6.  
  7. Set the No. 1 cylinder to Top Dead Center (TDC) for the compression stroke. Verify that the TDC marks are correctly aligned. Once the engine is set in this position, it must not be disturbed.
  8.  
  9. Remove the distributor as an assembly.
  10.  
  11. Loosen the valve adjusting screws.
  12.  
  13. Cover the timing belt with a clean shop towel to protect it from engine oil. If the belt is contaminated with oil, it must be replaced.
  14.  
  15. Remove the camshaft holder bolts. Unscrew the bolts two turns at a time in a crisscross pattern to prevent damaging the valves, camshaft, or rocker arm assembly.
  16.  

The rocker arms and shafts are an assembly; they must be removed from the engine as a unit. To prevent warpage, always follow the torque sequence carefully when removing or installing the rocker shaft assembly.

  1. Remove the rocker arm and shaft assemblies. Do not remove the camshaft holder bolts. The bolts keep the camshaft bearing caps, springs, and rocker arms in place on the shafts.
  2.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt loosening sequence-1.6L (D16Y7) engine

  1. If the rocker arms or shafts are to be replaced, identify the parts as they are removed from the shafts to ensure reinstallation in the original location.
  2.  

To install:

  1. Verify that the engine is set to TDC/compression for the No. 1 cylinder. The camshaft key-way faces up when the engine is at TDC/compression.
  2.  
  3. Lubricate the camshaft journals and lobes with clean engine oil. Install a new camshaft seal if necessary.
  4.  
  5. Remove the oil control orifice. Thoroughly clean it and install it with a new O-ring.
  6.  
  7. Assemble the rocker arms, shafts, and camshaft bearing caps.
  8.  
  9. Apply sealant to the mating surfaces of the No. 1 and No. 5 camshaft bearing caps. Do not allow the sealant to cure before the rocker arm assembly is installed.
  10.  
  11. Set the rocker arm assembly in place. Apply engine oil to the holder bolt threads, then loosely install the bolts. Tighten each bolt in a two step crisscross pattern to ensure that the rockers do not bind on the valves. Tighten the 8mm bolts to 14 ft. lbs. (20 Nm). Tighten the 6mm bolts to 8.7 ft. lbs. (12 Nm).
  12.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt tightening sequence-1.6L (D16Y7) engine

  1. Verify that the engine is at TDC/compression for the No. 1 piston and install the distributor.
  2.  
  3. Adjust the valves and tighten the locknuts to 14 ft. lbs. (20 Nm).
  4.  
  5. Install the valve cover and upper timing belt cover.
  6.  
  7. Reconnect the negative battery cable.
  8.  
  9. Check the ignition timing and adjust if necessary. Tighten the distributor mounting bolts to 17 ft. lbs. (24 Nm).
  10.  

1.6L (D16Y8) Engine


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Fig. Remove the bolts from the rocker assembly



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Fig. Remove the lost motion assembly holder



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Fig. View of the lost motion assembly holder



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Fig. Lost motion assembly



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Fig. Lost motion assembly holder bolt locations



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Fig. Removal of the rocker assembly



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Fig. Rocker arm assembly

  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the ignition wires. Remove the spark plugs and note their cylinder assignments.
  4.  
  5. Remove the valve cover.
  6.  
  7. Rotate the crankshaft to set the No. 1 cylinder to Top Dead Center (TDC) for the compression stroke. The white TDC mark on the crankshaft pulley aligns with the TDC pointers on the lower timing belt cover.
  8.  
  9. Remove the distributor from the cylinder head.
  10.  
  11. Loosen the valve adjusting screws.
  12.  
  13. Label and disconnect the VTEC solenoid valve connector.
  14.  
  15. Loosen the camshaft holder bolts two turns at a time in a crisscross pattern to prevent damaging the valves or rocker assembly.
  16.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt loosening sequence-1.6L (D16Y8) engine

  1. Remove the rocker arm and shaft assemblies together with the camshaft holders and the lost motion assembly holder. Do not remove the rocker shaft bolts yet. The bolts keep the bearing caps, springs, and rocker arms in place on the shafts.
  2.  

The rocker arms and shafts are an assembly; they must be removed from the engine as a unit. Always follow the torque sequence carefully when installing the rocker shaft assembly.

  1. Remove the camshaft holder bolts from the rocker arm and shaft assembly. Remove the lost motion assembly holder.
  2.  
  3. Bundle the intake rocker arm assemblies with rubber bands so they don't separate when the intake rocker shaft is removed.
  4.  
  5. Disassemble the rocker arm and shaft assemblies. Label the parts as they are removed from the shafts to ensure reinstallation in the original location.
  6.  
  7. Disassemble the rocker arm assemblies taking care not to mix up any of the parts. Inspect the rocker arm synchronizing pistons by pushing them with your fingers. If the pistons don't move smoothly in their rocker arm bores, replace the rocker arm assembly.
  8.  
  9. Apply oil to the synchronizing pistons and reassemble the rocker arms. Bundle the rocker arm assemblies with rubber bands to prevent the parts from separating.
  10.  
  11. Remove each lost motion assembly from its port in the lost motion assembly holder. Inspect each lost motion assembly by pushing down on its piston. If the piston doesn't move smoothly, replace the lost motion assembly. Lost motion assemblies cannot be bled like hydraulic lash adjusters.
  12.  
  13. Install the lost motion assemblies back into the lost motion assembly holder.
  14.  

To install:

  1. Verify that the engine is set at TDC/compression for the No. 1 cylinder.
  2.  
  3. Lubricate the camshaft journals and lobes. Coat the rocker shafts and camshaft holders with fresh oil.
  4.  
  5. Remove the oil control orifice. Thoroughly clean it and reinstall it with a new O-ring.
  6.  



Click image to see an enlarged view

Fig. Camshaft seal and oil control orifice-1.6L (D16Y8) engine

  1. Install a new camshaft seal if necessary.
  2.  
  3. Assemble the rocker arm and shaft assemblies. Be sure the intake shaft collars and exhaust shaft springs are in the proper locations.
  4.  
  5. After the rocker arms and shafts are assembled, cut the rubber bands and remove them from the intake rockers. Be sure that no rubber band fragments are left in the engine.
  6.  
  7. Install the lost motion assembly holder onto the camshaft holder. Apply fresh oil to the threads of camshaft holder bolts, then install them.
  8.  
  9. Apply liquid gasket to the cylinder head mating surfaces of the No. 1 and No. 5 camshaft holders. Don't allow the sealant to cure before installation.
  10.  
  11. Set the rocker arm and shaft assembly in place. Install and hand-tighten the bolts. Tighten each bolt two turns at a time in the crisscross sequence to ensure that the rockers do not bind on the valves. Tighten the 8mm rocker arm bolts to 14 ft. lbs. (20 Nm). Tighten the 6mm bolts to 9 ft. lbs. (12 Nm).
  12.  



Click image to see an enlarged view

Fig. Rocker arm/shaft bolt tightening sequence-1.6L (D16Y8) engine

  1. Starting with the No. 1 cylinder at TDC/compression, adjust the valve clearances. After the clearance has been reached, tighten the adjuster locknuts to 14 ft. lbs. (20 Nm). Set the No. 3, No. 4, and No. 2 cylinders at TDC/compression, then adjust their valve clearances.

    Intake: 0.007-0.009 in. (0.18-0.22mm)
     
    Exhaust: 0.009-0.011 in. (0.23-0.27mm)
     

  2.  
  3. Remove the VTEC solenoid valve, then remove the filter. Install a new VTEC solenoid valve filter. Tighten the solenoid valve bolts to 9 ft. lbs. (12 Nm) and reconnect the solenoid valve connectors.
  4.  
  5. Rotate the crankshaft to set the No. 1 cylinder at TDC/compression. Then, manually inspect the operation of each of the VTEC intake rocker arms:
    1. Push the in on the No. 1 cylinder's mid-intake rocker arm.
    2.  
    3. Verify that the mid-intake rocker arm moves independently of the primary and secondary intake rocker arms.
    4.  
    5. Repeat the rocker arm inspection for the other three cylinders with each cylinder set at TDC/compression.
    6.  

  6.  
  7. Rotate the crankshaft back to TDC/compression for the No. 1 cylinder. Install the distributor, but do not tighten the mounting bolts yet.
  8.  
  9. Tighten the crankshaft pulley to 134 ft. lbs. (181 Nm).
  10.  
  11. Install the valve cover. Be sure the gasket is in good condition, and apply sealant to the corners where the gasket meets the camshaft holders.
  12.  
  13. Install the spark plugs and reconnect the ignition wires.
  14.  
  15. Drain the engine oil and remove the oil filter. Install a new oil filter and refill the engine with fresh oil.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Warm the engine up to normal operating temperature.
  20.  
  21. Check the ignition timing and adjust it if necessary. Then, tighten the distributor mounting bolts to 17 ft. lbs. (24 Nm).
  22.  
  23. Check all fluid levels. Test drive the vehicle and observe the engine RPM changes at various speeds.
  24.  

1.6L (B16A2) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the ignition wires.
  4.  
  5. Rotate the crankshaft to set the engine at Top Dead Center (TDC) for the compression stroke of the No. 1 cylinder. The white TDC mark on the crankshaft pulley should align with the pointer on the lower timing belt cover.
  6.  
  7. Remove the strut brace.
  8.  
  9. Remove the intake air duct.
  10.  
  11. Loosen the power steering pump adjusting bolt to release the belt tension. Slip the belt off the pulleys. Loosen the air conditioner and alternator adjusting bolts, and slip their belts off the crankshaft pulley.
  12.  
  13. Use a floor jack padded with a block of wood to support the engine.
  14.  
  15. Remove the engine ground cable.
  16.  
  17. Unbolt and remove the engine side mount.
  18.  
  19. Remove the valve cover and the upper timing belt cover.
  20.  
  21. Verify that the engine is set at Top Dead Center (TDC)/compression. Loosen the timing belt tensioner bolt 180°. Then, remove the crankshaft pulley, the lower timing cover, and timing belt.
  22.  


WARNING
Inspect the timing belt for signs of cracked and broken teeth, as well as oil or coolant contamination. If the timing belt is damaged, or has been in contact with oil or coolant, it must be replaced to avoid potential failure.

  1. Remove the distributor.
  2.  
  3. Disconnect and remove the VTEC solenoid valve. Remove the solenoid filter and inspect it for clogging.
  4.  
  5. Remove the camshaft sprockets and back cover.
  6.  
  7. Loosen the camshaft holder plate bolts in a crisscross sequence working toward the middle of the cylinder head.
  8.  
  9. Loosen the valve adjusting screws.
  10.  
  11. Lift the camshaft holder plates and holder from the cylinder head. The holder bolts will keep the components together. Note the positions of each camshaft holder for reassembly.
  12.  
  13. Lift the camshafts from the cylinder head. Mark the exhaust and intake camshafts so that they will not be confused.
  14.  
  15. Hold each rocker arm assembly together with a rubber band to prevent them from separating.
  16.  
  17. Remove the intake and exhaust rocker shaft orifices from the cylinder head. The rocker shaft orifices are different and should be identified when removed. Thoroughly clean the orifices and reinstall them with new O-rings.
  18.  
  19. Remove the rocker arm shaft sealing bolts and discard the washers.
  20.  
  21. Insert 12mm bolts into the rocker arm shafts. Remove each rocker arm set while slowly pulling out the rocker arm shaft.
  22.  

Tag each rocker arm set to assure installation in their original locations.



Click image to see an enlarged view

Fig. Removing the rocker arms-1.6L (B16A2) engines

  1. Inspect the rocker arm pistons. If they do not move smoothly, replace the rocker arm assembly.
  2.  
  3. Remove the two lost motion assemblies from the cylinder head. Inspect each lost motion assembly by pushing the plunger with your finger. Replace the lost motion assembly if it does not move smoothly.
  4.  

To install:

  1. Install the two lost motion assemblies to the cylinder head.
  2.  
  3. Apply engine oil to the rocker arm pistons, then bundle the rocker arms with a rubber band. Apply a light coat of clean engine oil to the rocker arms.
  4.  
  5. Position the rocker arms in their original locations if they are being reused. If new assembles are being used, place them in the cylinder head.
  6.  
  7. Lightly coat the rocker arm shafts with clean engine oil, then install the rocker arm shafts into the cylinder head. A 12mm bolt can be installed into the end of the rocker arm shafts to aid in their installation. Be sure to install the shafts in the proper positions. Remove the 12mm bolts from the rocker arm shafts, if used.
  8.  
  9. Clean and install the rocker arm shaft orifices with new O-rings. If the holes in the rocker arm shafts are not aligned, screw a 12mm bolt into the end of the shaft to position the shaft.
  10.  
  11. Install the sealing bolts with new washers. Tighten the bolts to 47 ft. lbs. (64 Nm).
  12.  



Click image to see an enlarged view

Fig. Camshaft holder bolt torque sequences-1.6L (B16A2) engines

  1. Lubricate the camshaft lobes and journals with clean engine oil.
  2.  
  3. Set the camshafts into the cylinder head. Both the intake and exhaust camshafts should be installed with their key-ways pointing straight up.
  4.  
  5. Lubricate and install new camshaft seals. Apply liquid gasket to a new camshaft end-plug and install it. If the end-plug is marked, the mark should be aligned with the cylinder head surface.
  6.  
  7. Apply liquid gasket to the cylinder head mating surfaces of the No. 1 and No. 5 camshaft holders, then install them, along with No. 2, 3, and 4 holders. Be sure to pay attention to the following points:

    Do not apply oil to the holder mating surface of camshaft seals.
     
    The arrows marked on the camshaft holders should point to the timing belt.
     

  8.  
  9. Install the camshaft holder plates.
  10.  
  11. Lubricate the threads of the 10mm holder bolts. Then, install all the camshaft holder bolts, but don't tighten them yet.
  12.  
  13. Evenly hand-tighten the camshaft holders. Be sure that the rocker arms are properly positioned on the valve stems.
  14.  
  15. Use a two-step crisscross pattern to tighten the camshaft holder bolts. Begin tightening with the bolts in the middle of the cylinder head, and work toward the outer edges. Final torque specifications are as follows:

    8mm bolts 20 ft. lbs. (28 Nm).
     
    6mm bolts to 7-8 ft. lbs. (10-11 Nm)
     

  16.  
  17. Verify that the camshaft key-ways are pointing straight up and that the engine is at TDC/compression for the No. 1 cylinder. Fit the camshaft sprocket keys into their key-ways.
  18.  
  19. Install the back cover and push the camshaft pulleys onto the camshafts. Then, tighten the sprocket retaining bolts to 41 ft. lbs. (57 Nm).
  20.  
  21. Install and tension the timing belt.
  22.  
  23. Install the lower timing cover and the crankshaft pulley. Tighten the pulley bolt to 130 ft. lbs. (180 Nm).
  24.  
  25. Adjust the valve clearance.
  26.  
  27. Inspect the VTEC rocker arms for smooth and independent movement.
  28.  
  29. Install the VTEC solenoid valve with a new filter. Tighten the valve mounting bolts to 9 ft. lbs. (12 Nm).
  30.  
  31. Install the distributor.
  32.  
  33. Clean the valve cover gasket surfaces. Fit the gasket into the groove of the valve cover.
  34.  
  35. Apply liquid gasket to the rubber seal at the eight corners where the gaskets meet the camshaft holders. Don't allow the sealant to cure before installing the cylinder head cover.
  36.  
  37. Install the cylinder head cover and engine ground cable. Be sure the contact surfaces are clean and do not touch surfaces where liquid gasket has been applied.
  38.  
  39. Tighten the valve cover nuts in to 7 ft. lbs. (10 Nm) in a crisscross sequence.
  40.  
  41. Install the upper timing cover.
  42.  
  43. Install the accessory drive belts and adjust their tensions.
  44.  
  45. Install the engine side mount and tighten the two new nuts to 54 ft. lbs. (75 Nm) and tighten the bolt attaching the mount to the vehicle to 54 ft. lbs. (74 Nm).
  46.  
  47. Install the strut bar and tighten the mounting bolts to 16 ft. lbs. (22 Nm).
  48.  
  49. Reconnect the ignition wires.
  50.  
  51. Drain the engine oil. Install a new oil filter and refill the engine with fresh oil.
  52.  
  53. Reconnect the negative battery cable.
  54.  
  55. Warm the engine up to its normal operating temperature. Then, check and adjust the ignition timing. Tighten the distributor mounting bolts to 17 ft. lbs. (24 Nm).
  56.  

 
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