How to Replace the Rocker Arms / Shafts on a 1996 - 2000 Honda Civic LX / Del Sol 1.6L 4 Cyl D16Y5 Engine
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How to Replace the Rocker Arms / Shafts on a 1996 - 2000 Honda Civic LX / Del Sol 1.6L 4 Cyl D16Y5 Engine

How to replace the rocker arms / shafts on a 1996 - 2000 Honda Civic LX / del Sol 1.6L 4 cyl D16Y5 engine.

To remove:

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. Label and disconnect the ignition wires. Remove the spark plugs and note their cylinder assignments.
  3. Remove the valve cover.
  4. 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.
  5. Remove the distributor.
  6. Loosen the valve adjusting screws.
  7. Label and disconnect the VTEC solenoid valve connector.
  8. Loosen the camshaft holder bolts two turns at a time in a crisscross pattern to prevent damaging the valves or rocker assembly.
  9. 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. 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.
  10. Remove the camshaft holder bolts from the rocker arm and shaft assembly.
  11. Bundle the intake rocker arm assemblies with rubber bands so they don't separate when the intake rocker shaft is removed.
  12. Disassemble the rocker arm and shaft assemblies. Label the parts as they are removed from the shafts to ensure reinstallation in the original location.
  13. 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.
  14. 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.
  15. 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.

To install:

  1. Verify that the engine is set at TDC/compression for the No. 1 cylinder.
  2. Lubricate the camshaft journals and lobes. Coat the rocker shafts and camshaft holders with oil.
  3. Remove the oil control orifice. Thoroughly clean it and reinstall it with a new O-ring.
  4. Install a new camshaft seal if necessary.
  5. Assemble the rocker arm and shaft assemblies. Be sure the intake shaft collars and exhaust shaft springs are in the proper locations.
  6. 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.
  7. Apply fresh oil to the threads of camshaft holder bolts, then install them.
  8. 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.
  9. 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).
  10. 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)
  11. 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.
  12. 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: A. Move the No. 1 cylinder's secondary intake rocker arm up and down. B. Verify that the secondary intake rocker arm moves independently of the primary intake rocker arm. C. Repeat the rocker arm inspection for the other three cylinders with each cylinder set at TDC/compression.
  13. Rotate the crankshaft back to TDC/compression for the No. 1 cylinder. Install the distributor, but do not tighten the mounting bolts yet.
  14. Tighten the crankshaft pulley bolt to 134 ft. lbs. (181 Nm).
  15. 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.
  16. Install the spark plugs and reconnect the ignition wires.
  17. Drain the engine oil and remove the oil filter. Install a new oil filter and refill the engine with fresh oil.
  18. Connect the negative battery cable.
  19. Warm the engine up to normal operating temperature.
  20. Check the ignition timing and adjust it if necessary. Then, tighten the distributor mounting bolts to 17 ft. lbs. (24 Nm).
  21. Check all fluid levels. Test drive the vehicle and observe the engine RPM changes at various speeds.

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