CYLINDER HEAD

• HEADINGS
  • Special Tools
  • Component Location Index
  • Engine Compression Inspection
  • VTEC Rocker Arm Test
  • VTC Actuator Inspection
  • Valve Clearance Adjustment
  • Crankshaft Pulley Removal and Installation
    • Removal
    • Installation
  • Cam Chain Removal
  • Cam Chain Installation
  • Auto-Tensioner Removal and Installation
    • Removal
    • Installation
  • Chain Case Oil Seal Installation
  • Cam Chain Inspection
  • CKP Pulse Plate Replacement
  • Cylinder Head Cover Removal
  • Cylinder Head Cover Installation
  • Cylinder Head Removal
  • CMP Pulse Plate A Replacement
  • CMP Pulse Plate B Replacement
  • VTC Actuator, Exhaust Camshaft Sprocket Replacement
    • Removal
    • Installation
  • Cylinder Head Inspection for Warpage
  • Rocker Arm Assembly Removal
  • Rocker Arm and Shaft Disassembly/Reassembly
  • Rocker Arm and Shaft Inspection
  • Camshaft Inspection
  • Valve, Spring, and Valve Seal Removal
  • Valve Inspection
  • Valve Stem-to-Guide Clearance Inspection
  • Valve Guide Replacement
  • Valve Seat Reconditioning
  • Valve, Spring, and Valve Seal Installation
  • Rocker Arm Assembly Installation
  • Cylinder Head Installation
• FIGURES
  • Fig. 1: Identifying Special Tools
  • Fig. 2: Identifying Engine Replacement Components Location (1 Of 3)
  • Fig. 3: Identifying Engine Replacement Components Location (2 Of 3)
  • Fig. 4: Identifying Engine Replacement Components Location (3 Of 3)
  • Fig. 5: Attaching Compression Gauge To Spark Plug Hole
  • Fig. 6: Identifying Secondary Rocker Arm And Mid Rocker Arm
  • Fig. 7: Identifying VTEC Air Stopper
  • Fig. 8: Identifying Secondary Rocker Arm, Mid Rocker Arm, Primary Rocker Arm And Secondary Rocker Arm
  • Fig. 9: Identifying Advance Hole And Retard Hole In No. 1 Camshaft Journal
  • Fig. 10: Applying Air To Advance Hole
  • Fig. 11: Checking VTC Actuator
  • Fig. 12: Aligning Punch Mark On VTC Actuator And Exhaust Camshaft Sprocket
  • Fig. 13: Identifying Intake And Exhaust Valves
  • Fig. 14: Inserting Feeler Gauge Between Adjusting Screw And End Of Valve Stem
  • Fig. 15: Identifing Adjusting Screw
  • Fig. 16: Identifying Crankshaft Position
  • Fig. 17: Identifying Crankshaft Position
  • Fig. 18: Identifying Crankshaft Position
  • Fig. 19: Identifying Holder Handle And Holder Attachment
  • Fig. 20: Identifying Cleaning And Lubricating Points
  • Fig. 21: Identifying Holder Handle And Holder Attachment
  • Fig. 22: Tightening Crankshaft Pulley An Additional 90°
  • Fig. 23: Turning Crankshaft To TDC Mark With Pointer
  • Fig. 24: Aligning No. 1 Piston TDC Marks On VTC Actuator And Exhaust Camshaft Sprocket
  • Fig. 25: Identifying Crankshaft Position Sensor Connector And VTC Oil Control Solenoid Valve Connector
  • Fig. 26: Identifying Ground Cable And Upper Bracket
  • Fig. 27: Identifying Side Engine Mount Bracket
  • Fig. 28: Identifying Chain Case And CKP Pulse Plate
  • Fig. 29: Turning Crankshaft Counterclockwise
  • Fig. 30: Aligning Holes On Lock And Auto-Tensioner
  • Fig. 31: Identifying Auto-Tensioner With Bolts
  • Fig. 32: Identifying Cam Chain Guide
  • Fig. 33: Identifying Cam Chain Guide And Tensioner Arm
  • Fig. 34: Aligning TDC Mark On Crankshaft Sprocket With Pointer On Engine Block
  • Fig. 35: Aligning Punch Mark On VTC Actuator And Exhaust Camshaft Sprocket
  • Fig. 36: Identifying Camshaft Lock Pin Set And Pulse Plate
  • Fig. 37: Aligning Colored Link Plate With Mark On Crankshaft Sprocket
  • Fig. 38: Identifying Cam Chain On VTC Actuator And Exhaust Camshaft Sprocket
  • Fig. 39: Identifying Cam Chain Guide And Tensioner Arm W/Torque Specification
  • Fig. 40: Identifying Auto-Tensioner W/Torque Specification
  • Fig. 41: Identifying Cam Chain Guide W/Torque Specification
  • Fig. 42: Identifying Lock Pin
  • Fig. 43: Identifying Camshaft Lock Pin Set
  • Fig. 44: Identifying Crankshaft Position (CKP) Pulse Plate
  • Fig. 45: Applying Liquid Gasket To Engine Block Mating Surface
  • Fig. 46: Applying Liquid Gasket To Oil Pan Mating Surface
  • Fig. 47: Identifying Chain Case W/Torque Specification
  • Fig. 48: Identifying Engine Block
  • Fig. 49: Identifying Side Engine Mount Bracket With Torque Specification
  • Fig. 50: Tightening Upper Bracket Bolts In Sequence W/Torque Specifications
  • Fig. 51: Identifying Crankshaft Position Sensor Connector And VTC Oil Control Solenoid Valve Connector
  • Fig. 52: Identifying Chain Case Cover
  • Fig. 53: Turning Crankshaft Counterclockwise
  • Fig. 54: Aligning Holes On Lock And Auto-Tensioner
  • Fig. 55: Identifying Auto-Tensioner And Bolts
  • Fig. 56: Identifying Auto-Tensioner And Bolts
  • Fig. 57: Identifying Lock Pin
  • Fig. 58: Applying Liquid Gasket To Chain Case Mating Surface
  • Fig. 59: Identifying Chain Case Cover W/Torque Specification
  • Fig. 60: Driving Oil Seal Into Chain Case
  • Fig. 61: Measuring Distance Between Chain Case Surface And Oil Seal
  • Fig. 62: Measuring Tensioner Rod Length
  • Fig. 63: Identifying CKP Pulse Plate
  • Fig. 64: Identifying Intake Manifold Cover
  • Fig. 65: Identifying Vacuum Line Bolts
  • Fig. 66: Identifying Cylinder Head Nuts
  • Fig. 67: Identifying Cylinder Head Cover Gasket
  • Fig. 68: Applying Liquid Gasket To Chain Case And No. 5 Rocker Shaft Holder Mating Surface
  • Fig. 69: Identifying Cylinder Head Cover And Spark Plug Seals
  • Fig. 70: Tightening Cylinder Head Cover Bolts In Sequence
  • Fig. 71: Identifying Dipstick And Breather Hose W/Torque Specification
  • Fig. 72: Identifying Intake Manifold Cover W/Torque Specification
  • Fig. 73: Identifying Intake Air Temperature Sensor Connector Vacuum Hose And Breather Pipe
  • Fig. 74: Identifying Quick-Connect Fitting Cover And Fuel Feed Hose
  • Fig. 75: Identifying Connecting Pipe Bolt
  • Fig. 76: Identifying Evaporative Emission Canister Hose And Brake Booster Vacuum Hose
  • Fig. 77: Identifying Positive Crankcase Ventilation Hose And Ground Cable
  • Fig. 78: Identifying Upper Radiator Hose And Heater Hoses
  • Fig. 79: Identifying EVAP Canister Purge Valve Bracket And Bolts
  • Fig. 80: Identifying Cylinder Head Bolts In Sequence
  • Fig. 81: Identifying Intake Camshaft With Open-End Wrench
  • Fig. 82: Identifying Camshaft Position Pulse Plate W/Torque Specification
  • Fig. 83: Identifying Exhaust Camshaft With Open-End Wrench
  • Fig. 84: Identifying Camshaft Position Pulse Plate W/Torque Specification
  • Fig. 85: Identifying Camshaft Mounting Bolts
  • Fig. 86: Identifying Camshaft Mounting Bolts
  • Fig. 87: Checking Cylinder Head For Warpage (1 Of 2)
  • Fig. 88: Checking Cylinder Head For Warpage (2 Of 2)
  • Fig. 89: Identifying Rocker Arm Adjusting Screws
  • Fig. 90: Identifying Camshaft Holder Bolts In Sequence
  • Fig. 91: Identifying Rocker Arm Assembly Bolts
  • Fig. 92: Identifying Rocker Arm And Shaft Components
  • Fig. 93: Measuring Diameter Of Shaft
  • Fig. 94: Identifying Shaft Diameter
  • Fig. 95: Measuring Inside Diameter Of Rocker Arm
  • Fig. 96: Inspecting Rocker Arm Pistons
  • Fig. 97: Tightening Bolts In Sequence
  • Fig. 98: Checking Camshaft End Play
  • Fig. 99: Measuring Widest Portion Of Plastigage
  • Fig. 100: Checking Camshaft Total Runout
  • Fig. 101: Measuring Cam Lobe Height
  • Fig. 102: Taping Valve Retainer
  • Fig. 103: Removing Valve Cotters
  • Fig. 104: Identifying Valve Guide Seal Remover
  • Fig. 105: Removing Valve Seal
  • Fig. 106: Identifying Valve Dimension
  • Fig. 107: Measuring Guide-To-Stem Clearance
  • Fig. 108: Identifying Air-Impact Valve Guide Driver
  • Fig. 109: Heating Cylinder Head
  • Fig. 110: Removing Guide
  • Fig. 111: Installing Guide
  • Fig. 112: Rotating Reamer
  • Fig. 113: Reaming Valve Seats In Cylinder Head Using Valve Seat Cutter
  • Fig. 114: Identifying Valve Seat Cutter Angle
  • Fig. 115: Applying Prussian Blue Compound To Valve Face
  • Fig. 116: Identifying Valve Stem Installed Height
  • Fig. 117: Identifying Valve Seals
  • Fig. 118: Compressing Spring
  • Fig. 119: Tapping End Of Valve Stem
  • Fig. 120: Applying Liquid Gasket to Cylinder Head Mating Surface
  • Fig. 121: Identifying Rocker Arm Assembly And Bolts
  • Fig. 122: Identifying Camshafts, Camshaft Holders And Cam Chain Guide
  • Fig. 123: Tightening Bolts In Sequence
  • Fig. 124: Identifying Coolant Separator
  • Fig. 125: Identifying Cylinder Head Gasket And Dowel Pins
  • Fig. 126: Aligning TDC Mark On Crankshaft Sprocket With Pointer On Engine Block
  • Fig. 127: Identifying Cylinder Head Bolt Diameter
  • Fig. 128: Identifying Cylinder Head Bolts Tightening Sequence
  • Fig. 129: Identifying Cylinder Head Bolt Tightening Steps
  • Fig. 130: Identifying EVAP Canister Purge Valve Bracket, Bolt W/Torque Specifications
  • Fig. 131: Identifying Upper Radiator Hose And Heater Hoses
  • Fig. 132: Identifying Positive Crankcase Ventilation Hose And Ground Cable W/Torque Specification
  • Fig. 133: Identifying Water Bypass Hose W/Torque Specification
  • Fig. 134: Identifying Evaporative Emission Canister Hose And Brake Booster Vacuum Hose
  • Fig. 135: Identifying Quick-Connect Fitting Cover And Fuel Feed Hose
  • Fig. 136: Identifying Intake Air Temperature Sensor Connector, Vacuum Hose And Breather Pipe
• TABLES
  • CAM LOBE HEIGHT SPECIFICATION

2004-08 ENGINE

Cylinder Head - TSX

Special Tools

Fig. 1: Identifying Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Component Location Index

Fig. 2: Identifying Engine Replacement Components Location (1 Of 3)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig. 3: Identifying Engine Replacement Components Location (2 Of 3)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig. 4: Identifying Engine Replacement Components Location (3 Of 3)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Engine Compression Inspection

NOTE:

After the inspection, you must reset the engine control module (ECM)/the powertrain control module (PCM). Otherwise, the ECM/PCM will continue to stop the fuel injectors from functioning.

1. Warm up the engine to normal operating temperature (the radiator fan comes on at least twice).
2. Turn the ignition switch OFF.
3. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM) ).
4. Turn the ignition switch ON (II).
5. '07-08 models: Make sure the HDS communicates with the vehicle and the ECM/PCM. If it doesn't communicate, troubleshoot the DLC circuit (see '07-08 MODELS ).
6. Select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
7. Turn the ignition switch OFF.
8. Remove the four ignition coils (see IGNITION COIL REMOVAL/INSTALLATION ).
9. Remove the four spark plugs (see SPARK PLUG INSPECTION ).
10. Attach the compression gauge to the spark plug hole.

    Fig. 5: Attaching Compression Gauge To Spark Plug Hole
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Open the throttle fully, then crank the engine with the starter motor and measure the compression.

    Compression Pressure:

    Above 930 kPa (9.5 kgf/cm² , 135 psi)

12. Measure the compression of the remaining cylinders.

    Maximum Variation:

    Within 200 kPa (2.0 kgf/cm² , 29 psi)

13. If the compression is not within specifications, check the following items, then remeasure the compression.
    • Damaged or worn valves and seats
    • Damaged cylinder head gasket
    • Damaged or worn piston rings
    • Damaged or worn piston and cylinder bore
14. Remove the compression gauge from the spark plug hole.
15. Install the four spark plugs (see SPARK PLUG INSPECTION ).
16. Install the four ignition coils (see IGNITION COIL REMOVAL/INSTALLATION ).
17. Select ECM/PCM reset (see ECM/PCM RESET ) to cancel the ALL INJECTORS OFF on the HDS.
18. Do the ECM/PCM idle learn procedure (see ECM/PCM IDLE LEARN PROCEDURE ).

VTEC Rocker Arm Test

Special Tools Required

• Air pressure regulator 07AAJ-PNAA101
• VTEC air adapter 07ZAJ-PNAA101
• VTEC air stopper 07ZAJ-PNAA200
• Air joint adapter 07ZAJ-PNAA300

1. Start the engine and let it run for 5 minutes, then turn the ignition switch OFF.
2. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
3. Set the No. 1 piston at top dead center (TDC) (see step 4 on CAM CHAIN REMOVAL ).
4. Move the secondary rocker arm (A) for the No. 1 cylinder. The secondary rocker arm should move independently of the mid rocker arm (B).
   • If the secondary rocker arm does not move, remove the mid, primary, and secondary rocker arms as an assembly, and check that the pistons in the rocker arms move smoothly. If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly, and test.
   • If the secondary rocker arm moves freely, go to step 5.

     Fig. 6: Identifying Secondary Rocker Arm And Mid Rocker Arm
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Repeat step 4 on the remaining secondary rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 6.
6. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4.0 kgf/cm² , 57 psi).
7. Inspect the valve clearance (see VALVE CLEARANCE ADJUSTMENT ).
8. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B).

   Fig. 7: Identifying VTEC Air Stopper
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Remove the No. 3 camshaft holder bolts, and install the VTEC air adapters (C) finger-tight.
10. Connect the air joint adapter (D) and air pressure regulator (E).
11. Loosen the valve on the regulator, and apply the specified air pressure.

    Specified Air Pressure:

    290 kPa (3.0 kgf/cm² , 42 psi)

    NOTE:

    If the rocker arm piston does not move after applying air pressure, move the rocker arm up and down manually by rotating the crankshaft clockwise.

12. With the specified air pressure applied, move the secondary rocker arm (A) for the No. 1 cylinder. The mid rocker arm (B), primary rocker arm (C), and secondary rocker arm should move together.
    • If the mid and primary rocker arms do not move together with the secondary rocker arm, remove the mid, primary, and secondary rocker arms as an assembly, and check that the pistons in the rocker arms move smoothly. If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly, and retest.

      Fig. 8: Identifying Secondary Rocker Arm, Mid Rocker Arm, Primary Rocker Arm And Secondary Rocker Arm
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Remove the VTEC air stopper and VTEC air adapters.
14. Tighten the camshaft holder mounting bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
15. Tighten the sealing bolt to 20 N.m (2.0 kgf.m, 15 lbf.ft).
16. Install the cylinder head cover (see CYLINDER HEAD COVER INSTALLATION ).

VTC Actuator Inspection

1. Remove the cam chain (see CAM CHAIN REMOVAL ).
2. Loosen the rocker arm adjusting screws (see step 2 on ROCKER ARM ASSEMBLY REMOVAL ).
3. Remove the camshaft holder (see step 3 on ROCKER ARM ASSEMBLY REMOVAL ).
4. Remove the intake camshaft.
5. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator counterclockwise. If not locked, turn the VTC actuator clockwise until it stops, then recheck it. If it is still not locked, replace the VTC actuator.
6. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape.

   Fig. 9: Identifying Advance Hole And Retard Hole In No. 1 Camshaft Journal
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Punch a hole in the tape over one of the advance holes.
8. Apply air to the advance hole to release the lock.

   Fig. 10: Applying Air To Advance Hole
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator.

   Fig. 11: Checking VTC Actuator
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Remove the tape and adhesive residue from the No. 1 camshaft journal.
11. Make sure the punch marks on the VTC actuator and exhaust camshaft sprocket are facing up, then set the camshafts in the rocker shaft holder (see step 6 on ROCKER ARM ASSEMBLY INSTALLATION ).
12. Set the camshaft holders and chain guide B in place (see step 7 on ROCKER ARM ASSEMBLY INSTALLATION ).
13. Tighten the camshaft holder bolts to the specified torque (see step 8 on ROCKER ARM ASSEMBLY INSTALLATION ).
14. Hold the camshaft, and turn the VTC actuator clockwise until you hear it click. Make sure to lock the VTC actuator by turning it.
15. Install the cam chain (see CAM CHAIN INSTALLATION ).
16. Adjust the valve clearance (see VALVE CLEARANCE ADJUSTMENT ).

Valve Clearance Adjustment

Special Tools Required

Tappet adjust wrench set 07MAA-PR70100

NOTE:

Adjust the valves only when the cylinder head temperature is less than 100°F (38°C).

1. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
2. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket.

   Fig. 12: Aligning Punch Mark On VTC Actuator And Exhaust Camshaft Sprocket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Select the correct thickness feeler gauge for the valves you're going to check.

   Valve Clearance

   Intake: 0.21-0.25 mm (0.008-0.010 in.)

   Exhaust: 0.25-0.29 mm (0.010-0.011 in.)

   Fig. 13: Identifying Intake And Exhaust Valves
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, then slide it back and forth, you should feel a slight amount of drag.

   Fig. 14: Inserting Feeler Gauge Between Adjusting Screw And End Of Valve Stem
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. If you feel too much or too little drag, loosen the locknut with the tappet adjust wrench set, and turn the adjusting screw until the drag on the feeler gauge is correct.

   Fig. 15: Identifing Adjusting Screw
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Tighten the locknut to the specified torque.

   Specified Torque

   Intake: 20 N.m (2.0 kgf.m, 15 lbf.ft)

   Apply new engine oil to the nut threads.

   Exhaust: 14 N.m (1.4 kgf.m, 10 lbf.ft)

   Apply new engine oil to the nut threads.

7. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).

   Fig. 16: Identifying Crankshaft Position
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Check and, if necessary, adjust the valve clearance on No. 3 cylinder.
9. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).

   Fig. 17: Identifying Crankshaft Position
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Check and, if necessary, adjust the valve clearance on No. 4 cylinder.
11. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).

    Fig. 18: Identifying Crankshaft Position
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Check and, if necessary, adjust the valve clearance on No. 2 cylinder.
13. Install the cylinder head cover (see CYLINDER HEAD COVER INSTALLATION ).

Crankshaft Pulley Removal and Installation

Special Tools Required

• Holder handle 07JAB-001020B
• Holder attachment, 50 mm 07NAB-001040A
• Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

Removal

1. Remove the front wheels.
2. Remove the splash shield (see step 26 on TRANSMISSION REMOVAL ).
3. Remove the drive belt (see DRIVE BELT REPLACEMENT ).
4. Hold the crankshaft pulley with holder handle (A) and holder attachment (B).

   Fig. 19: Identifying Holder Handle And Holder Attachment
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the bolt with a 19 mm socket (C) and breaker bar, then remove the crankshaft pulley.

Installation

1. Clean the crankshaft pulley (A), crankshaft (B), bolt (C), and washer (D). Lubricate new engine oil as shown.

   Fig. 20: Identifying Cleaning And Lubricating Points
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B).

   Fig. 21: Identifying Holder Handle And Holder Attachment
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Tighten the bolt to 50 N.m (5.0 kgf.m, 37 lbf.ft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench.
4. Mark the bolt head (A) and the crankshaft pulley (B) as shown, then tighten the bolt an additional 90° (The mark on the bolt head line up with the mark on the crankshaft pulley).

   Fig. 22: Tightening Crankshaft Pulley An Additional 90°
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Install the drive belt (see DRIVE BELT REPLACEMENT ).
6. Install the splash shield (see step 25 on TRANSMISSION INSTALLATION ).
7. Install the front wheels.

Cam Chain Removal

NOTE:

Keep the cam chain away from magnetic fields.

1. Remove the front wheels.
2. Remove the splash shield (see step 26 on TRANSMISSION REMOVAL ).
3. Remove the drive belt (see DRIVE BELT REPLACEMENT ).
4. Turn the crankshaft pulley so its top dead center (TDC) mark (A) lines up with the pointer (B).

   Fig. 23: Turning Crankshaft To TDC Mark With Pointer
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
6. Check that the No. 1 piston TDC marks (A) on the variable valve timing control (VTC) actuator and exhaust camshaft sprocket are aligned.

   Fig. 24: Aligning No. 1 Piston TDC Marks On VTC Actuator And Exhaust Camshaft Sprocket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the crankshaft pulley (see CRANKSHAFT PULLEY REMOVAL AND INSTALLATION ).
8. Disconnect the crankshaft position (CKP) sensor connector (A) and VTC oil control solenoid valve connector (B).

   Fig. 25: Identifying Crankshaft Position Sensor Connector And VTC Oil Control Solenoid Valve Connector
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Remove the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
10. Support the engine with a jack and wood block under the oil pan.
11. Remove the ground cable (A), and remove the upper bracket (B).

    Fig. 26: Identifying Ground Cable And Upper Bracket
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Remove the side engine mount bracket.

    Fig. 27: Identifying Side Engine Mount Bracket
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Remove the chain case (A), then remove CKP pulse plate (B).

    Fig. 28: Identifying Chain Case And CKP Pulse Plate
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Loosely install the crankshaft pulley.
15. Turn the crankshaft counterclockwise to compress the auto-tensioner.

    Fig. 29: Turning Crankshaft Counterclockwise
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

16. Align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (0.05 in.) diameter pin or lock pin (P/N 14511-PNA-003) (C) into the holes. Turn the crankshaft clockwise to secure the pin.

    Fig. 30: Aligning Holes On Lock And Auto-Tensioner
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Remove the auto-tensioner.

    Fig. 31: Identifying Auto-Tensioner With Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Remove the crankshaft pulley.
19. Remove the cam chain guide B.

    Fig. 32: Identifying Cam Chain Guide
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Remove the cam chain guide A and tensioner arm (B).

    Fig. 33: Identifying Cam Chain Guide And Tensioner Arm
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Remove the cam chain.

Cam Chain Installation

Special Tools Required

Camshaft lock pin set 07AAB-RWCA120

NOTE:

Keep the cam chain away from magnetic fields. Before this procedure, check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator counterclockwise. If not locked, turn the VTC actuator clockwise until it stops, then recheck it. If it is still not locked, replace the VTC actuator.

1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

   Fig. 34: Aligning TDC Mark On Crankshaft Sprocket With Pointer On Engine Block
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Set the camshafts to TDC. The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket.

   Fig. 35: Aligning Punch Mark On VTC Actuator And Exhaust Camshaft Sprocket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. To hold the intake camshaft, insert one of the pins (C) from the camshaft lock pin set into the maintenance hole in the camshaft position (CMP) pulse plate A and through the hole in the No. 5 rocker shaft holder (D).

   Fig. 36: Identifying Camshaft Lock Pin Set And Pulse Plate
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. To hold the exhaust camshaft, insert the other pin from the camshaft lock pin set into the maintenance hole in the camshaft position (CMP) pulse plate B and through the hole in the No. 5 rocker shaft holder.
5. Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket.

   Fig. 37: Aligning Colored Link Plate With Mark On Crankshaft Sprocket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Install the cam chain on the VTC actuator and the exhaust camshaft sprocket with the punch marks (A) aligned with the center of the two colored link plates (B).

   Fig. 38: Identifying Cam Chain On VTC Actuator And Exhaust Camshaft Sprocket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Install the cam chain guide A and the tensioner arm (B).

   Fig. 39: Identifying Cam Chain Guide And Tensioner Arm W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Install the auto-tensioner.

   Fig. 40: Identifying Auto-Tensioner W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Install cam chain guide B.

   Fig. 41: Identifying Cam Chain Guide W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Remove the pin or lock pin (P/N 14511-PNA-000) from the auto-tensioner.

    Fig. 42: Identifying Lock Pin
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Remove the camshaft lock pin set (P/N 07AAB-RWCA120).

    Fig. 43: Identifying Camshaft Lock Pin Set
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Install the crankshaft position (CKP) pulse plate.

    Fig. 44: Identifying Crankshaft Position (CKP) Pulse Plate
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal (see CHAIN CASE OIL SEAL INSTALLATION ).
14. Remove all of the old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
15. Clean and dry the chain case mating surfaces.
16. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 45: Applying Liquid Gasket To Engine Block Mating Surface Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Apply liquid gasket to the engine block upper surface contact areas (A) on the chain case and lower block upper surface contact areas (B) on the chain case.
18. Apply liquid gasket, P/N 08717-0004,08718-0001, 08717-0003, or 08718-0009, evenly to the oil pan mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket.

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 46: Applying Liquid Gasket To Oil Pan Mating Surface Courtesy of AMERICAN HONDA MOTOR CO., INC.

19. Install the new O-ring (A) on the chain case. Set the edge of the chain case (B) to the edge of the oil pan (C), then install the chain case on the engine block (D). Wipe off all of the excess liquid gasket on the oil pan and chain case mating surface.

    NOTE:

    When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Wait at least 30 minutes before filling the engine with oil. Do not run the engine within 3 hours after installing the chain case. Fig. 47: Identifying Chain Case W/Torque Specification Courtesy of AMERICAN HONDA MOTOR CO., INC. Fig. 48: Identifying Engine Block Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Install the side engine mount bracket.

    Fig. 49: Identifying Side Engine Mount Bracket With Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Install the upper bracket (A), then tighten the bolts in the sequence shown.

    Fig. 50: Tightening Upper Bracket Bolts In Sequence W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Install the ground cable (B).
23. Install the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
24. Connect the CKP sensor connector (A) and VTC oil control solenoid valve connector (B).

    Fig. 51: Identifying Crankshaft Position Sensor Connector And VTC Oil Control Solenoid Valve Connector
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

25. Install the crankshaft pulley (see INSTALLATION ).
26. Install the cylinder head cover (see CYLINDER HEAD COVER INSTALLATION ).
27. Install the drive belt (see DRIVE BELT REPLACEMENT ).
28. Install the splash shield (see step 25 on TRANSMISSION INSTALLATION ).
29. Install the front wheels.
30. Do the CKP pattern clear/CKP learn procedure (see CRANK (CKP) PATTERN CLEAR/CRANK (CKP) PATTERN LEARN ).

Auto-Tensioner Removal and Installation

Removal

1. Remove the chain case cover.

   Fig. 52: Identifying Chain Case Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Turn the crankshaft counterclockwise to compress the auto-tensioner.

   Fig. 53: Turning Crankshaft Counterclockwise
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (0.05 in.) diameter pin or lock pin (P/N 14511-PNA-003) (C) into the holes. Turn the crankshaft clockwise to secure the pin.

   Fig. 54: Aligning Holes On Lock And Auto-Tensioner
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the auto-tensioner.

   Fig. 55: Identifying Auto-Tensioner And Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Installation

1. Install the auto-tensioner.

   Fig. 56: Identifying Auto-Tensioner And Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the pin or lock pin (P/N 14511-PNA-003) from the auto-tensioner.

   Fig. 57: Identifying Lock Pin
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove old liquid gasket from the chain case cover mating surfaces, bolts, and bolt holes.
4. Clean and dry the chain case cover mating surfaces.
5. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the chain case mating surface of the chain case cover. Install the component within 5 minutes of applying the liquid gasket.

   NOTE:

   If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 58: Applying Liquid Gasket To Chain Case Mating Surface Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Install the chain case cover.

   NOTE:

   Wait at least 30 minutes before filling the engine with oil. Do not run the engine within 3 hours after installing the chain case cover. Fig. 59: Identifying Chain Case Cover W/Torque Specification Courtesy of AMERICAN HONDA MOTOR CO., INC.

Chain Case Oil Seal Installation

Special Tools Required

• Handle driver 07749-0010000
• Attachment, 52 x 55 mm 07746-0010400

1. Use the handle driver and attachment to drive a new oil seal squarely into the chain case to the specified installed height.

   Fig. 60: Driving Oil Seal Into Chain Case
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Measure the distance between the chain case surface (A) and oil seal (B).

   Oil Seal Installed Height:

   33.0-33.7 mm (1.30-1.33 in.)

   Fig. 61: Measuring Distance Between Chain Case Surface And Oil Seal
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Cam Chain Inspection

1. Remove the right front wheel.
2. Remove the splash shield.
3. Remove the drive belt (see DRIVE BELT REPLACEMENT ).
4. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
5. Remove the crankshaft pulley (see CRANKSHAFT PULLEY REMOVAL AND INSTALLATION ).
6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector (see step 8 on CAM CHAIN REMOVAL ).
7. Remove the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
8. Support the engine with a jack and wood block under the oil pan.
9. Remove the ground cable, and remove the upper bracket (see step 11 on CAM CHAIN REMOVAL ).
10. Remove the side engine mount bracket (see step 12 on CAM CHAIN REMOVAL ).
11. Remove the chain case (see step 13 on CAM CHAIN REMOVAL ).
12. Measure the tensioner rod length between the tensioner body and bottom of the flat surface section on the tensioner rod. If the length is more than the service limit, replace the cam chain and oil pump chain.

    Tensioner Rod Length

    Service Limit: 13.5 mm (0.53 in.)

    Fig. 62: Measuring Tensioner Rod Length
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal (see CHAIN CASE OIL SEAL INSTALLATION ).
14. Remove all of the old liquid gasket from the chain case mating surfaces, bolt, and bolt holes.
15. Clean and dry the chain case mating surfaces.
16. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket (see step 16 on CAM CHAIN INSTALLATION ).

    NOTE:

    If you apply liquid gasket, P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new gasket.

17. Apply liquid gasket evenly to the engine block upper surface contact areas on the chain case and lower block upper surface contact areas on the chain case (see step 17 on CAM CHAIN INSTALLATION ).
18. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the oil pan mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket (see step 18 on CAM CHAIN INSTALLATION ).

    NOTE:

    If you apply liquid gasket, P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

19. Install the new O-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the engine block (see step 19 on CAM CHAIN INSTALLATION ). Wipe off the excess liquid gasket on the oil pan and chain case mating surface.

    NOTE:

    When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Wait at least 30 minutes before filling the engine with oil. Do not run the engine for at least 3 hours after installing the chain case.

20. Install the side engine mount bracket (see step 20 on CKP PULSE PLATE REPLACEMENT ).
21. Install the upper bracket and the ground cable (see step 21 on CKP PULSE PLATE REPLACEMENT ).
22. Install the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
23. Connect the CKP sensor connector and VTC oil control solenoid valve connector (see step 24 on CAM CHAIN INSTALLATION ).
24. Install the crankshaft pulley (see INSTALLATION ).
25. Install the cylinder head cover (see CYLINDER HEAD COVER INSTALLATION ).
26. Install the drive belt (see DRIVE BELT REPLACEMENT ).
27. Install the splash shield (see step 25 on TRANSMISSION INSTALLATION ).
28. Install the right front wheel.
29. Do the CKP pattern clear/CKP learn procedure (see CRANK (CKP) PATTERN CLEAR/CRANK (CKP) PATTERN LEARN ).

CKP Pulse Plate Replacement

1. Remove the right front wheel.
2. Remove the splash shield (see step 26 on TRANSMISSION REMOVAL ).
3. Remove the drive belt (see DRIVE BELT REPLACEMENT ).
4. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
5. Remove the crankshaft pulley (see CRANKSHAFT PULLEY REMOVAL AND INSTALLATION ).
6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector (see step 8 on CAM CHAIN REMOVAL ).
7. Remove the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
8. Support the engine with a jack and wood block under the oil pan.
9. Remove the ground cable, then remove the upper bracket (see step 11 on CAM CHAIN REMOVAL ).
10. Remove the side engine mount bracket (see step 12 on CAM CHAIN REMOVAL ).
11. Remove the chain case (see step 13 on CAM CHAIN REMOVAL ).
12. Remove the CKP pulse plate.

    Fig. 63: Identifying CKP Pulse Plate
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Install the CKP pulse plate.
14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal (see CHAIN CASE OIL SEAL INSTALLATION ).
15. Remove all of the old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
16. Clean and dry the chain case mating surfaces.
17. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket (see step 16 on CAM CHAIN INSTALLATION ).

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

18. Apply liquid gasket evenly to the engine block upper surface contact areas on the chain case and lower block upper surface contact areas on the chain case (see step 17 on CAM CHAIN INSTALLATION ).
19. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the oil pan mating surface of the chain case.

    Install the component within 5 minutes of applying the liquid gasket (see step 18 on CAM CHAIN INSTALLATION ).

    NOTE:

    If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

20. Install the new O-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the engine block (see step 19 on CAM CHAIN INSTALLATION ). Wipe off the excess liquid gasket on the oil pan and chain case mating surface.

    NOTE:

    When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Wait at least 30 minutes before filling the engine with oil. Do not run the engine within 3 hours after installing the chain case.

21. Install the side engine mount bracket (see step 20 on CAM CHAIN INSTALLATION ).
22. Install the upper bracket and the ground cable (see step 21 on CAM CHAIN INSTALLATION ).
23. Install the VTC oil control solenoid valve (see VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION ).
24. Connect the CKP sensor connector and VTC oil control solenoid valve connector (see step 24 on CAM CHAIN INSTALLATION ).
25. Install the crankshaft pulley (see INSTALLATION ).
26. Install the cylinder head cover (see CYLINDER HEAD COVER INSTALLATION ).
27. Install the drive belt (see DRIVE BELT REPLACEMENT ).
28. Install the splash shield (see step 25 on TRANSMISSION INSTALLATION ).
29. Install the right front wheel.
30. Do the CKP pattern clear/CKP learn procedure (see CRANK (CKP) PATTERN CLEAR/CRANK (CKP) PATTERN LEARN ).

Cylinder Head Cover Removal

1. Remove the engine cover.

   Fig. 64: Identifying Intake Manifold Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the four ignition coils (see IGNITION COIL REMOVAL/INSTALLATION ).
3. Remove the two bolts (A) securing the vacuum line.

   Fig. 65: Identifying Vacuum Line Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the bolt (B) securing the power steering (P/S) hose bracket.
5. Remove the dipstick (C) and disconnect the breather hose (D).
6. Remove the cylinder head cover.

   Fig. 66: Identifying Cylinder Head Nuts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Cylinder Head Cover Installation

1. Thoroughly clean the head cover gasket and the groove.
2. Install the head cover gasket (A) in the groove of the cylinder head cover (B).

   Fig. 67: Identifying Cylinder Head Cover Gasket
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Check that the mating surfaces are clean and dry.
4. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the chain case and the No. 5 rocker shaft holder mating surface.

   Install the component within 5 minutes of applying the liquid gasket.

   NOTE:

   If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 68: Applying Liquid Gasket To Chain Case And No. 5 Rocker Shaft Holder Mating Surface Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.

   Fig. 69: Identifying Cylinder Head Cover And Spark Plug Seals
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.
7. Tighten the bolts in three steps. In the final step tighten all bolts, in sequence, to 12 N.m (1.2 kgf.m, 8.8 lbf.ft).

   NOTE:

   Wait at least 30 minutes before filling the engine with oil. Do not run the engine within 3 hours after installing the head cover. Fig. 70: Tightening Cylinder Head Cover Bolts In Sequence Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Install the dipstick (A) and breather hose (B).

   Fig. 71: Identifying Dipstick And Breather Hose W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Tighten the bolt (C) securing the power steering (P/S) hose bracket.
10. Tighten the two bolts (D) securing the vacuum line.
11. Install the four ignition coils (see IGNITION COIL REMOVAL/INSTALLATION ).
12. Check that all tubes, hoses, and connectors are installed correctly.
13. Install the engine cover.

    Fig. 72: Identifying Intake Manifold Cover W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Cylinder Head Removal

NOTE:

Use fender covers to avoid damaging painted surfaces. To avoid damaging the wires and terminals, unplug the wiring connectors carefully while holding the connector portion. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before loosening the cylinder head bolts. Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

1. Relieve the fuel pressure (see FUEL PRESSURE RELIEVING ).
2. Drain the engine coolant, '04-05 models (see '04-05 MODELS ), '06-08 models (see '06-08 MODELS ).
3. Remove the drive belt (see DRIVE BELT REPLACEMENT ).
4. Disconnect the intake air temperature (IAT) sensor connector (A).

   Fig. 73: Identifying Intake Air Temperature Sensor Connector Vacuum Hose And Breather Pipe
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Disconnect the vacuum hose (B) and breather pipe (C), then remove the air intake duct (D).
6. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose (B) (see FUEL LINE/QUICK-CONNECT FITTING REMOVAL ).

   Fig. 74: Identifying Quick-Connect Fitting Cover And Fuel Feed Hose
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the intake manifold, '04-05 models (see REMOVAL ('04-05 MODELS) ) or '06-08 models (see REMOVAL ('06-08 MODELS) ).
8. Remove the exhaust manifold (see EXHAUST MANIFOLD REMOVAL AND INSTALLATION ).
9. Remove the bolt (A) securing the connecting pipe.

   Fig. 75: Identifying Connecting Pipe Bolt
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Disconnect the water bypass hose (B).
11. Disconnect the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

    Fig. 76: Identifying Evaporative Emission Canister Hose And Brake Booster Vacuum Hose
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Disconnect the positive crankcase ventilation (PCV) hose (A) and remove the ground cable (B).

    Fig. 77: Identifying Positive Crankcase Ventilation Hose And Ground Cable
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Remove the upper radiator hose (A) and heater hoses (B).

    Fig. 78: Identifying Upper Radiator Hose And Heater Hoses
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Remove the engine wire harness connectors and wire harness clamps from the cylinder head.
    • Four injector connectors
    • Engine coolant temperature (ECT) sensor connector ('04-05 models)
    • Engine coolant temperature (ECT) sensor 1 connector ('06-08 models)
    • Camshaft position (CMP) sensor A/B connectors
    • Rocker arm oil control solenoid (VTEC solenoid valve) connector
    • Rocker arm oil pressure switch (VTEC oil pressure switch) connector
15. Remove the two bolts (A) securing the EVAP canister purge valve bracket and remove the bolt (B) securing the harness bracket.

    Fig. 79: Identifying EVAP Canister Purge Valve Bracket And Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

16. Remove the cam chain (see CAM CHAIN REMOVAL ).
17. Remove the rocker arm assembly (see ROCKER ARM ASSEMBLY REMOVAL ).
18. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time, repeat the sequence until all bolts are loosened.

    Fig. 80: Identifying Cylinder Head Bolts In Sequence
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

19. Remove the cylinder head.

CMP Pulse Plate A Replacement

1. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
2. Hold the intake camshaft with an open-end wrench, then loosen the bolt.

   Fig. 81: Identifying Intake Camshaft With Open-End Wrench
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the camshaft position (CMP) pulse plate A.

   Fig. 82: Identifying Camshaft Position Pulse Plate W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the CMP pulse plate A in the reverse order of removal.

CMP Pulse Plate B Replacement

1. Remove the cylinder head cover (see CYLINDER HEAD COVER REMOVAL ).
2. Hold the exhaust camshaft with an open-end wrench, then loosen the bolt.

   Fig. 83: Identifying Exhaust Camshaft With Open-End Wrench
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the camshaft position (CMP) pulse plate B.

   Fig. 84: Identifying Camshaft Position Pulse Plate W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the CMP pulse plate B in the reverse order of removal.

VTC Actuator, Exhaust Camshaft Sprocket Replacement

Removal

1. Remove the cam chain (see CAM CHAIN REMOVAL ).
2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt.

   Fig. 85: Identifying Camshaft Mounting Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. If the VTC actuator is reused, do these steps.
   1. Remove the intake camshaft, and seal the advance holes and retard holes in the No. 1 camshaft journal with tape (see step 6 on VTC ACTUATOR INSPECTION ).
   2. Punch a hole in the tape over one of the advance holes (see step 7 on VTC ACTUATOR INSPECTION ).
   3. Apply air to the advance hole to release the lock (see step 8 on VTC ACTUATOR INSPECTION ).
   4. Remove the tape from the No. 1 camshaft journal.
4. Remove the VTC actuator and exhaust camshaft sprocket.

Installation

1. Install the VTC actuator and exhaust camshaft sprocket.

   NOTE:

   Installing the VTC actuator in the unlock position.

2. Apply new engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt, then install them.
3. Hold the camshaft with an open-end wrench, then tighten the mounting bolts.

   Specified Torque

   VTC Actuator Mounting Bolt: 113 N.m (11.5 kgf.m, 83 lbf.ft)

   Exhaust Camshaft Sprocket Mounting Bolt: 72 N.m (7.3 kgf.m, 53 lbf.ft)

   Fig. 86: Identifying Camshaft Mounting Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Hold the camshaft with an open-end wrench, and turn the VTC actuator clockwise until you hear it click. Make sure to lock the VTC actuator by turning it.
5. Install the cam chain (see CAM CHAIN INSTALLATION ).

Cylinder Head Inspection for Warpage

1. Remove the cylinder head (see CYLINDER HEAD REMOVAL ).
2. Inspect the camshaft (see CAMSHAFT INSPECTION ).
3. Check the cylinder head for warpage. Measure along the edges, and three ways across the center.
   • If warpage is less than 0.05 mm (0.002 in.), cylinder head resurfacing is not required.
   • If 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 104 mm (4.09 in.).

   Cylinder Head Height

   Standard (New): 103.95-104.05 mm 4.093-4.096 in.)

   Fig. 87: Checking Cylinder Head For Warpage (1 Of 2)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Fig. 88: Checking Cylinder Head For Warpage (2 Of 2)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rocker Arm Assembly Removal

1. Remove the cam chain (see CAM CHAIN REMOVAL ).
2. Loosen the rocker arm adjusting screws (A).

   Fig. 89: Identifying Rocker Arm Adjusting Screws
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts in sequence two turns at a time, in the sequence shown.

   NOTE:

   Bolt (1) is not on all engines.

   Fig. 90: Identifying Camshaft Holder Bolts In Sequence
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the cam chain guide B, camshaft holders, and camshafts.
5. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

   Fig. 91: Identifying Rocker Arm Assembly Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rocker Arm and Shaft Disassembly/Reassembly

NOTE:

Identify parts as they are removed to ensure reinstallation in their original location. Inspect the rocker shafts and rocker arms (see ROCKER ARM AND SHAFT INSPECTION ). If reused the rocker arms must be installed in their original location. When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders and rocker arms on the shaft. Prior to reassembling, clean all the parts insolvent, dry them, and apply new engine oil to any contact points. Bundle the rocker arms with rubber bands to keep them together as a set. When replacing the intake rocker arm assembly, remove the fastening hardware from the new intake rocker arm assembly. Fig. 92: Identifying Rocker Arm And Shaft Components Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rocker Arm and Shaft Inspection

1. Remove the rocker arm assembly (see ROCKER ARM ASSEMBLY REMOVAL ), then disassemble the rocker arm assembly (see ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY ).
2. Measure the diameter of the shaft at the first rocker location.

   Fig. 93: Measuring Diameter Of Shaft
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Zero the gauge (A) to the shaft diameter.

   Fig. 94: Identifying Shaft Diameter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition.

   Rocker Arm-to-Shaft Clearance

   Standard (New): 0.025-0.052 mm 0.0010-0.0020 in.)

   Service Limit: 0.08 mm (0.003 in.)

   Fig. 95: Measuring Inside Diameter Of Rocker Arm
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Repeat for all rocker arms and both shafts. If the clearance is beyond the service the limit, replace the rocker shaft and all out of service limit rocker arms. If any VTEC rocker arm needs replacement, replace the rocker arms (primary, mid, and secondary), as a set.
6. Inspect the rocker arm pistons (A). Push on each piston manually.

   If it does not move smoothly, replace the rocker arm as a set.

   NOTE:

   Apply new engine oil to the rocker arm pistons when reassembling.

   Fig. 96: Inspecting Rocker Arm Pistons
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Install the rocker arm assembly (see ROCKER ARM ASSEMBLY INSTALLATION ).

Camshaft Inspection

NOTE:

Do not rotate the camshaft during inspection.

1. Remove the rocker arm assembly (see ROCKER ARM ASSEMBLY REMOVAL ).
2. Put the rocker shaft holders, camshaft, and camshaft holders on the cylinder head, then tighten the bolts in sequence to the specified torque.

   NOTE:

   If the engine does not have bolt (21), skip it and continue the torque sequence.

   Specified Torque

   • 8 mm Bolts: 22 N.m (2.2 kgf.m, 16 lbf.ft)
   • 6 mm Bolts: 12 N.m (1.2 kgf.m, 8.8 lbf.ft)
   • 6 mm Bolts: (21), (22), (23)

   Fig. 97: Tightening Bolts In Sequence
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head.
4. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth and read the end play. If the end play is beyond the service limit, replace the cylinder head and recheck. If it is still beyond the service limit, replace the camshaft.

   Camshaft End Play

   Standard (New): 0.05-0.20 mm (0.002-0.008 in.)

   Service Limit: 0.4 mm (0.02 in.)

   Fig. 98: Checking Camshaft End Play
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Loosen the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.
6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.
7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.
8. Install the camshaft holders, then tighten the bolts to the specified sequence as shown in step 2.
9. Remove the camshaft holders. Measure the widest portion of plastigage on each journal.
   • If the camshaft-to-holder clearance is within limits, go to step 11.
   • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head.
   • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 10.

   Camshaft-to-Holder Oil Clearance

   Standard (New):

   • No. 1 Journal: 0.030-0.069 mm (0.001-0.003 in.)
   • No. 2,3,4,5 Journals: 0.060-0.099 mm (0.002-0.004 in.)

   Service Limit: 0.15 mm (0.006 in.)

   Fig. 99: Measuring Widest Portion Of Plastigage
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Check the total runout with the camshaft supported on V-blocks.
    • If the total runout of the camshaft is within the service limit, replace the cylinder head.
    • If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the service limit, replace the cylinder head.

    Camshaft Total Runout

    Standard (New): 0.03 mm (0.001 in.) max.

    Service Limit: 0.04 mm (0.002 in.)

    Fig. 100: Checking Camshaft Total Runout
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Measure cam lobe height.

    Cam Lobe Height Standard (New):

    CAM LOBE HEIGHT SPECIFICATION
    

    	INTAKE	EXHAUST
    PRI	33.416 mm (1.3156 in.)	32.994 mm (1.2990 in.)
    MID	35.032 mm (1.3792 in.)	35.090 mm (1.3815 in.)
    SEC	33.416 mm (1.3156 in.)	32.994 mm (1.2990 in.)
    PRI: Primary MID: Mid SEC: Secondary C/C: Cam Chain

    Fig. 101: Measuring Cam Lobe Height
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Valve, Spring, and Valve Seal Removal

Special Tools Required

Valve spring compressor attachment 07757-PJ1010A

Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position.

1. Remove the cylinder head (see CYLINDER HEAD REMOVAL ).
2. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve spring retainer to loosen the valve cotters.

   Fig. 102: Taping Valve Retainer
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Install the valve spring compressor attachment and valve spring compressor. Compress the valve spring, and remove the valve cotters.

   Fig. 103: Removing Valve Cotters
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the valve spring compressor, valve spring compressor attachment, valve spring retainer, and valve spring.
5. Install the valve guide seal remover.

   Fig. 104: Identifying Valve Guide Seal Remover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Remove the valve seal.

   Fig. 105: Removing Valve Seal
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Valve Inspection

1. Remove the valves (see VALVE, SPRING, AND VALVE SEAL REMOVAL ).
2. Measure the valve in these areas.

   Intake Valve Dimensions

   • A Standard (New): 34.85-35.15 mm (1.372-1.384 in.)
   • B Standard (New): 108.7-109.5 mm (4.280-4.311 in.)
   • C Standard (New): 5.475-5.485 mm (0.2156-0.2159 in.)

   C Service Limit: 5.445 mm (0.214 in.)

   Exhaust Valve Dimensions

   • A Standard (New): 29.85-30.15 mm (1.175-1.187 in.)
   • B Standard (New): 108.3-109.1 mm (4.264-4.295 in.)
   • C Standard (New): 5.450-5.460 mm (0.2146-0.2150 in.)

   C Service Limit: 5.42 mm (0.213 in.)

   Fig. 106: Identifying Valve Dimension
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Valve Stem-to-Guide Clearance Inspection

1. Remove the valves (see VALVE, SPRING, AND VALVE SEAL REMOVAL ).
2. Slide the valve out of its guide about 10 mm (0.39 in.), then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method).
   • If the measurement exceeds the service limit, recheck it using a new valve.
   • If the measurement is now within the service limit, reassemble using a new valve.
   • If the measurement with a new valve still exceeds the service limit, go to step 3.

   Intake Valve Stem-to-Guide Clearance

   • Standard (New): 0.06-0.11 mm (0.002-0.004 in.)
   • Service Limit: 0.16 mm (0.006 in.)

   Exhaust Valve Stem-to-Guide Clearance

   • Standard (New): 0.11-0.16 mm (0.004-0.006 in.)
   • Service Limit: 0.22 mm (0.009 in.)

   Fig. 107: Measuring Guide-To-Stem Clearance
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide.

   The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit.

   Intake Valve Stem-to-Guide Clearance

   • Standard (New): 0.030-0.055 mm (0.0012-0.0022 in.)
   • Service Limit: 0.08 mm (0.003 in.)

   Exhaust Valve Stem-to-Guide Clearance

   • Standard (New): 0.055-0.080 mm (0.0022-0.0031 in.)
   • Service Limit: 0.11 mm (0.004 in.)

Valve Guide Replacement

Special Tools Required

• Valve guide driver, 5.5 mm 07742-0010100
• Valve guide reamer, 5.5 mm 07HAH-PJ7A100

1. Inspect valve stem-to-guide clearance (see VALVE STEM-TO-GUIDE CLEARANCE INSPECTION ).
2. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the valve guide driver and a conventional hammer.

   Fig. 108: Identifying Air-Impact Valve Guide Driver
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for about an hour.
4. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); excessive heat may loosen the valve seats.

   Fig. 109: Heating Cylinder Head
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Working from the combustion chamber/ use the driver and an air hammer to drive the guide about 2 mm (0.1 in.) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver.

   Wear safety goggles or a face shield.

6. Turn the head over, and drive the guide out toward the camshaft side of the head.

   Fig. 110: Removing Guide
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. If a valve guide won't move, drill it out with an 8 mm (5/16 in.) bit, then try again. Drill guides only in extreme cases, you could damage the cylinder head if the guide breaks.
8. Remove the new guide(s) from the freezer, one at a time, as you need them.
9. Apply a thin coat of new engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head, use the valve guide driver to drive the guide in to the specified installed height (A) of the guide (B). If you have all 16 guides to do, you may have to reheat the head.

   Valve Guide Installed Height

   Intake: 15.2-16.2 mm (0.598-0.638 in.)

   Exhaust: 15.5-16.5 mm (0.610-0.650 in.)

   Fig. 111: Installing Guide
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. Coat both reamer and valve guide with cutting oil.
11. Rotate the reamer clockwise the full length of the valve guide bore.

    Fig. 112: Rotating Reamer
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve (see VALVE STEM-TO-GUIDE CLEARANCE INSPECTION ). Verify that a valve slides in the intake and exhaust valve guides without sticking.
15. Inspect the valve seating, if necessary renew the valve seat using a valve seat cutter (see VALVE SEAT RECONDITIONING ).

Valve Seat Reconditioning

1. Inspect valve stem-to-guide clearance (see VALVE STEM-TO-GUIDE CLEARANCE INSPECTION ). If the valve guides are worn, replace them (see VALVE GUIDE REPLACEMENT ) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a valve seat cutter.

   Fig. 113: Reaming Valve Seats In Cylinder Head Using Valve Seat Cutter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentric seat.
4. Bevel the upper and lower edges at the angles shown in the illustration. Check the width of the seat and adjust accordingly.

   Fig. 114: Identifying Valve Seat Cutter Angle
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters.

   Valve Seat Width

   Standard (New): 1.25-1.55 mm (0.049-0.061 in.)

   Service Limit: 2.00 mm (0.079 in.)

6. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times.

   Fig. 115: Applying Prussian Blue Compound To Valve Face
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat.
   • If it is too high (closer to the valve stem), you must make a second cut with the 67.5° cutter to move it down, then one more cut with the 45° cutter to restore seat width.
   • If it is too low (close to the valve edge), you must make a second cut with the 35° cutter (intake side) or the 30° cutter (exhaust side) to move it up, then make one more cut with the 45° cutter to restore seat width.

   NOTE:

   The final cut should always be made with the 45° cutter.

8. Insert the intake and exhaust valves in the head, and measure valve stem installed height (A).

   Intake Valve Stem Installed Height

   • Standard (New): 44.0-44.5 mm (1.73-1.75 in.)
   • Service Limit: 44.7 mm (1.76 in.)

   Exhaust Valve Stem Installed Height

   • Standard (New): 44.1-44.6 mm (1.74-1.76 in.)
   • Service Limit: 44.8 mm (1.76 in.)

   Fig. 116: Identifying Valve Stem Installed Height
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. If valve stem installed height is beyond the service limit, replace the valve and recheck. If it is still beyond the service limit, replace the cylinder head, the valve seat in the head is too deep.

Valve, Spring, and Valve Seal Installation

Special Tools Required

• Stem seal driver 07PAD-0010000
• Valve spring compressor attachment 07757-PJ1010A

1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the stem seal driver (B).

   NOTE:

   The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F). They are not interchangeable.

   Fig. 117: Identifying Valve Seals
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Install the valve spring and valve spring retainer. Place the end of the valve spring with closely wound coils toward the cylinder head.
6. Install the valve spring compressor attachment and valve spring compressor. Compress the spring, and install the valve cotters.

   Fig. 118: Compressing Spring
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the valve spring compressor and valve spring compressor attachment.
8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve cotters. Tap the valve stem only along its axis so you do not bend the stem.

   Fig. 119: Tapping End Of Valve Stem
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Rocker Arm Assembly Installation

1. Reassemble the rocker arm assembly (see ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY ).
2. Clean and dry the No. 5 rocker shaft holder mating surface.
3. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder head mating surface of the No. 5 rocker shaft holder. Install the component within 5 minutes of applying the liquid gasket.

   NOTE:

   If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. Fig. 120: Applying Liquid Gasket to Cylinder Head Mating Surface Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder head.

   Fig. 121: Identifying Rocker Arm Assembly And Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the bolts from the rocker shaft holder.
6. Make sure the punch marks on the variable valve timing control (VTC) actuator and exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. Apply new engine oil to the camshaft journals and lobes.

   Fig. 122: Identifying Camshafts, Camshaft Holders And Cam Chain Guide
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Set the camshaft holders (B) and cam chain guide B (C) in place.
8. Tighten the bolts in sequence to the specified torque.

   NOTE:

   If the engine does not have bolt (21), skip it and continue the torque sequence.

   Specified Torque

   8 mm Bolts: 22 N.m (2.2 kgf.m, 16 lbf.ft)

   6 mm Bolts: 12 N.m (1.2 kgf.m, 8.8 lbf.ft)

   6 mm Bolts: (21), (22), (23)

   Fig. 123: Tightening Bolts In Sequence
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Install the cam chain (see CAM CHAIN INSTALLATION ), then adjust the valve clearance (see VALVE CLEARANCE ADJUSTMENT ).

Cylinder Head Installation

Install the cylinder head in the reverse order of removal.

1. Install a new coolant separator in the engine block whenever the engine block is replaced.

   Fig. 124: Identifying Coolant Separator
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Clean the cylinder head and engine block surface.
3. Install a new cylinder head gasket (A) and dowel pins (B) on the engine block. Always use a new cylinder head gasket.

   Fig. 125: Identifying Cylinder Head Gasket And Dowel Pins
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

   Fig. 126: Aligning TDC Mark On Crankshaft Sprocket With Pointer On Engine Block
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Install the cylinder head on the engine block.
6. Measure the diameter of each cylinder head bolt at point A and point B.

   Fig. 127: Identifying Cylinder Head Bolt Diameter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt.
8. Apply new engine oil to the threads and flange of all cylinder head bolts.
9. Tighten the cylinder head bolts in sequence to 39 N.m (4.0 kgf.m, 29 lbf.ft). Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.

   Specified Torque: 39 N.m (4.0 kgf.m, 29 lbf.ft)

   Fig. 128: Identifying Cylinder Head Bolts Tightening Sequence
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

10. After torquing, tighten all cylinder head bolts in two steps (90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°.

    NOTE:

    Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

    Fig. 129: Identifying Cylinder Head Bolt Tightening Steps
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Install the rocker arm assembly (see ROCKER ARM ASSEMBLY INSTALLATION ).
12. Install the cam chain (see CAM CHAIN INSTALLATION ).
13. Tighten the two bolts (A) securing the evaporative emission (EVAP) canister purge valve bracket and the bolt (B) securing the harness brackets.

    Fig. 130: Identifying EVAP Canister Purge Valve Bracket, Bolt W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Install the engine wire harness connectors and wire harness clamps to the cylinder head.
    • Four injector connectors
    • Engine coolant temperature (ECT) sensor connector ('04-05 models)
    • Engine coolant temperature (ECT) sensor 1 connector ('06-08 models)
    • Camshaft position (CMP) sensor A/B connectors
    • Rocker arm oil control solenoid (VTEC solenoid valve) connector
    • Rocker arm oil pressure switch (VTEC oil pressure switch) connector
15. Install the upper radiator hose (A) and heater hoses (B).

    Fig. 131: Identifying Upper Radiator Hose And Heater Hoses
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

16. Install the positive crankcase ventilation (PCV) hose (A) and ground cable (B).

    Fig. 132: Identifying Positive Crankcase Ventilation Hose And Ground Cable W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Install the water bypass hose (A).

    Fig. 133: Identifying Water Bypass Hose W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Tighten the bolt (B) securing the connecting pipe.
19. Install the exhaust manifold (see EXHAUST MANIFOLD REMOVAL AND INSTALLATION ).
20. Install the intake manifold, '04-05 models (see INSTALLATION ('04-05 MODELS) ) or '06-08 models (see INSTALLATION ('06-08 MODELS) ).
21. Install the EVAP canister hose (A) and brake booster vacuum hose (B).

    Fig. 134: Identifying Evaporative Emission Canister Hose And Brake Booster Vacuum Hose
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Connect the fuel feed hose (A) (see FUEL LINE/QUICK-CONNECT FITTING INSTALLATION ), then install the quick-connect fitting cover (B). Make sure the connector engages fully.

    Fig. 135: Identifying Quick-Connect Fitting Cover And Fuel Feed Hose
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

23. Install the air intake duct (A), then connect the intake air temperature (IAT) sensor connector (B), and install the vacuum hose (C) and breather pipe (D).

    Fig. 136: Identifying Intake Air Temperature Sensor Connector, Vacuum Hose And Breather Pipe
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

24. After installation, check that all tubes, hoses, and connectors are installed correctly.
25. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.
26. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open, '04-05 models (see step 6 on '04-05 MODELS ), '06-08 models (see step 6 on '06-08 MODELS ).
27. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see CRANK (CKP) PATTERN CLEAR/CRANK (CKP) PATTERN LEARN ).
28. Inspect the idle speed (see IDLE SPEED INSPECTION ).
29. Inspect the ignition timing (see IGNITION TIMING INSPECTION ).
30. Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the audio presets.
31. Set the clock (on vehicle without navigation).

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