06. valvetrain

\
EngineMechanical
CylinderHead
SpecialTools
6-2
Comoonent
LocationIndex
6-3
EngineCompression
Inspection
b-t'
VTECRocker
Arm Test ...........
............
6-7
VTCActuatorInspection
....................
6-8
ValveClearance
Adjustment
.............
6-9
Crankshaft
PulleyRemovaland Installation..............
6-11
C a mC h a i nR e m o v a l
. . . . . . . . . . . . . . . . . . .6. -. 1
. .2. . . .
C a mC h a i nI n s t a l l a t i o n
. . . . . . . . . . . . . . . .6. .-.1. .5. .
Auto-Tensioner
Removal/1nsta11ation
.........................
6-19
ChainCaseOil SealInstallation
........6-21
CyfinderHeadCoverRemoval
..........
6-22
CylinderHeadRemoval
.....................
6-23
WC Actuator.ExhaustCamshaftSorocket
R e paf c e m e n t
.........6-24
Head
Cylinder
Inspection
for Warpage......................
6-25
Rocker
Arm AssemblyRemoval.................................
6-26
Rocker
ArmsandShafts
Disassembly/Reassembly
..............
6-27
Rocker
ArmsandShaftsInspection............................
6-28
Camshaft
Inspection
..........................
6-29
Valves,Springs,andValveSealsRemoval................
6-31
ValveInsoection......................
...........
6-32
ValveStem-to-Guide
Clearance
Insoection...............
6-32
ValveGuideReolacement
.................
6-33
ValveSeatReconditioning
................
6-35
Valves,Springs,
andValveSealsInstallation............
6-37
Rocker
Arm AssemblvInstallation
.... 6-38
C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3
. .9. . . . . . . . . .
CylinderHeadCoverInstallation
......6-41
CylinderHead
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SpecialTools
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07JAB-0010204
07NAB-0010404
07VAE-001010A
OTZAJ.PNAAlOO
OTZAJ-PNAA2OO
I 07ZAJ-PNAA300
07742-0010100
07746-001o4oo
07749-0010000
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Regulator
Air Pressure
V a l v eG u i d eR e a m e r5, . 5m m
Socket,19 mm
H o l d e rH a n d l e
HolderAttachment,50 mm
Valve Spring CompressorAttachment
VTECAir Adapter
VTECAlr Stopper
Air Joint Adapter
V a l v eGu i d eD r i v e r , 5 . 5m m
Attachment,52 x 55 mm
Driver
OTAAJ.PNAA'IOO
OTHAH-PJ7O1OB
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Description
Tool Number
Ref. No.
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6-2
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ComponentLocationlndex
IGNITIONCOIL
COVER
CYLINDER
HEAD
COVER
page6-22
Removal,
page6-41
lnstallation,
CAM CHAIN
Bemoval,page6-'12
Installation,page6-15
frn
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CAM CHAINGUIDEB
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CAM CHAINGUIDEA
VALVE
VARIABLE
TIMINGCONTROL
twc) olL soLENotD
VALVE
PULLEY
CRANKSHAFT
R e p l a c e m e npt a
, g e6 1 1
TENSIONER
ARM
AUTO.TENSIONER
page6-'lI
Replacement,
O-RING
(cont'd)
6-3
CylinderHead
ComponentLocationIndex(cont'd)
CAMSHAFT
HOLDER
Fg
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LI T
fr
F]
CAMSHAFTPOSITION
ICMP}SENSOR
EEI
g-----
CAMCHAIN
GUIDEB
/
-"-oowetew
TOPDEADCENTER
(TDC)SENSOR
EXHAUSTCAMSHAFT
SPROCKET
Removal,page6 24
page6-25
Installation,
EXHAUSTCAMSHAFT
ROCKER
ARM
ASSEMBLY
Overhaul,page6 27
Inspection,page 6-28
6-4
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SPRING
RETAINER
vALvE
EXHAUSTVALVE
SEAL
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vALVE
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Replacement,
Page6-31
H e ,
|NTAKEVALVE
GUIDE
page6-33
Replacement,
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\*""'RArNERcovER
wcsrRArNER
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HEATSHIELD
HEAD
CYLINDER
Removal,page6'23
Inspection,page6-25
Installation,page6-39
EXHAUSTVALVE
Removal,page6-31
Installation,page6-37
INTAKEVALVE
Removal,page6 31
Installation,page6 37
CYLINDER
HEAD
GASKET
6-5
CylinderHead
EngineCompressionInspection
1 . W a r m u p t h e e n g i n et o n o r m a lo p e r a t i n g
temperature(coolingfan comes on).
\
9 . Open the throttlefully, then crankthe enginewith
the startermotor and measurethe compression.
2. Turn the ignition switch OFF.
3. Removethe intakemanifoldcover (seestep 1 on
page6-22).
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
1 0 .Measurethe compressionon the remaining
cylinders,
4, Disconnectall four injectorconnectors.
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
5. Startthe engine,and let it run until it stalls.
6 . R e m o v et h e i o u r i g n i t i o nc o i l s( s e ep a g e4 - 1 8 ) .
7. Removethe four spark plugs.
8. Attachthe compressiongaugeto the spark plug
note.
1 1 .lf the compressionis not within specifications,
checkthese items,then remeasurethe
compressron.
.
.
.
.
Damagedorworn valvesand seats
Damagedcylinder head gasket
Damagedor worn piston rings
Damagedorworn piston and cylinderbore
\-
V,
6-6
WEC RockerArmsTest
Special Tools Required
. Air pressureregulator07AAJ-PNAA100
. VTECair adaoter07ZAJ-PNAA100
. WEC air stoDoer07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300
1. Removethe cylinder headcover (seepage 6-22).
2. Set the No. 1 pistonat top dead center(TDC)(see
step 1 on page6-12).
3. Verify that the intakeprimary rockerarm (A) moves
independentlyof the intakesecondaryrockerarm
(B).
Repeatstep 3 on the remainingintakeprimary
rockerarms with each piston at TDC.When all the
primary rockerarms passthe test, go to step 5.
Checkthat the air pressureon the shop air
compressorgauge indicatesover 400 kPa
(4 kgflcm',57 psi).
6 . Inspectthe valve clearance(seepage 6-9).
7 . Removethe sealingbolt (A)from the relief hole,
and installthe VTECair stopper(B).
OTAAJ.PNAAlOO
D
OTZAJ-PNAA3OO
. lf the intakeprimary rockerarm does not move,
removethe primary and secondaryrockerarms
as an assemblyand checkthat the pistonsin the
secondaryand primary rockerarms move
smoothly.lf any rockerarm needs replacing,
replacethe primary and secondaryrockerarms
as an assemblv,and test.
. lfthe intakeprimary rockerarm moves freely,go
to step 4.
OTZAJ.PNAAlOO
Removethe No. 2 and No. 3 camshaftholder bolts,
and installthe VTECair adapters(C)finger-tight.
Connectthe air joint adapter(D),and air pressure
regulatorwith a 0-100psi gauge (E).
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl
'10.
Loosenthe valve on the regulator,and apply the
specifiedair pressure.
Specified air pressure:
290 kPa 13.0kgt/cm', 42 psi)
NOTE:lf the synchronizingpiston does not move
after applyingair pressure;move the primary or
secondaryrockerarm up and down manuallyby
rotatingthe crankshaftclockwise.
1 1 . W i t h t h e s p e c i f i e da i r p r e s s u r ea p p l i e d m
, o v et h e
i n t a k ep r i m a r yr o c k e ra r m ( A ) f o r t h e N o , 1 c y l i n d e r .
The primary rockerarm and secondaryrockerarm
( B )s h o u l dm o v e t o g e t h e r .
lf the intakesecondaryrockerarm does not move,
removethe primary and secondaryrockerarms as
an assembly,and checkthat the pistonsin the
primary and secondaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primary and secondaryrockerarms as
an assembly,and test.
VTGActuator Inspection
'11.
Removethe cylinder headcover (seepage 6-22lr.
2. Removethe auto-tensioner(seepage6-19).
3. Loosenthe rockerarm adjustingscrewslsee step 2
on page6-26).
4. Removethe camshaftholder (seestep 3 on page 6-
26t.
5. Removethe intakecamshaft.
6, Checkthat the variablevalve timing control (VTC)
actuatoris lockedby turning the VTCactuator
clockwiseand counterclockwise.
lf the VTC actuator
is not locked,replacethe VTCactuator.
7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n
the No. 1 camshaftjournal with tape.
Puncha hole through the tape over one of the
advanceholes.
1 2 .Removethe specialtools.
1 3 .Tightenthe camshaftholder mounting boltslo
22N m 12.2kgf.m, 16 lbf.ft).
1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m ,
14 tbf.ft).
t5.
6-8
I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
ValveGlearanceAdiustment
9. Apply air to the advancehole to releasethe lock.
NOTE:Adjust the valvesonly when the cylinder head
temperatureis lessthan 100'F (38'C).
1. Removethe cylinderhead cover (seepage6-22).
2. Set the No. 1 piston at top dead center(TDC).The
punch mark (A) on the variablevalve timing control
(VTC)actuatorand the punch mark (B)on the
exhaustcamshaftsprocketshould be at the top.
Align the TDC marks (C)on the VTC actuatorand
exhaustcamshaftsprocket.
1 0 .Checkthat the VTCactuatormoves smoothly.lf the
VTC actuatordoes not move smoothly, replacethe
VTC acluator.
{cont'd)
6-9
GylinderHead
ValveClearanceAdjustment (cont'd)
3. Selectthe correctthickness
feelergaugefor the
valvesyou'regoingto check.
Intake: 0.21 0.25mm (0.008-0.010
in.)
Exhaust; 0.28 0.32mm (0.011 0.013in.)
\.
5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e
locknut(A),and turn the adjustingscrew {B) until
the drag on the feelergauge is correct..
Adiustingscrew locations:
EXHAUST
No. 1
No. 1
N o .2
No.3
N o .4
No.4
Tightenthe locknut,and recheckthe clearance.
Repeatthe adjustmentif necessary
7 . Rotatethe crankshaft180"clockwise(camshaft
p u l l e yt u r n s9 0 ' ) .
4. Insertthe feeler gauge {A) betweenthe adjusting
s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t
backand forth; you should feel a slight amount of
d rag.
t.
\-
8. Checkand, if necessary,adjustthe valve clearance
o n N o .3 c y l i n d e r .
6-10
I
CrankshaftPulleyRemovaland
Installation
9. Rotatethe crankshaft180"clockwise(camshaft
pullevturns 90').
Special Tools Required
. Holder handle07JAB-001020A
. Holderattachment,50 mm 07NAB-001040A
. Socket,19 mm 07JAA-001020,4
or a commercially
a v a i l a b l e1 9 m m s o c k e t
Removal
1. Removefront tires/wheels.
2. Removethe splashshield (seestep 23 on page 5-5).
3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r
attachment(B).
B
07NAB-001040A
1 0 .Checkand, if necessary,adjustthe valve clearance
on No.4 cylinder.
1 1 .Rotatethe crankshaft180"clockwise(camshaft
p u l l e yt u r n s9 0 " ) .
el
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(or
commercially
available)
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Removethe bolt with a 19 mm socket(C)and
breakerbar.
1 2 .Checkand, if necessary,adjustthe valve clearance
o n N o .2 c y l i n d e r .
Installthe cylinder headcover (seepage 6-41).
(cont'd)
6-11
CylinderHead
CrankshaftPulleyRemovaland
Installation(cont'dl
CamChainRemoval
a
NOTE:Keepthe cam chain away from magneticfields.
Installation
1. Cleanthe crankshaftpulley (A),crankshaft(B),bolt
(C).and washer (D).Lubricateas shown below.
1. Turn the crankshaftpulley so ils top dead center
( T D C )m a r k( A )l i n e su p w i t h t h e p o i n r e r( B ) .
. .: Clean
O; Lubricate
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2 . Removethe front tires/wheels.
I n s t a l l t h ec r a n k s h a fpt u l l e y ,a n d h o l dt h e p u l l e y
with holder handle(A) and holder attachment{B).
3 . R e m o v et h e s p l a s hs h i e l d .
- , , - - . = . - - - - - _ _ - - _
B
07NAB-0010iroA
\
A
07JAB-001020A
4. Removethe drive belt (seepage 4-26).
Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft)
with a torque wrench and 19 mm socket(C).Do not
use an impactwrench.
5. Removethe cylinder headcover (see page6-22).
6 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) .
5 . Install front tires/wheels.
\-
6-12
7. Disconnectthecrankshaftposition(CKP)sensor
connector{A) and variablevalvetiming control
{VTC)oil control solenoidvalve connector(B).
1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .
1 2 . R e m o v et h e c h a i nc a s e .
Removethe VTC oil control solenoidvalve (see
s t e p1 o n p a g e1 1 - 1 2 7 ) .
9 . Supportthe enginewith a iack and wood block
u n d e rt h e o i l p a n .
1 0 .Removethe ground cable (A).and removethe
upper bracket(B).
(cont'd)
6-13
CylinderHead
CamChainRemoval(cont'd)
Looselyinstallthe crankshaftpulley.
(
\
16. Removethe auto-tensioner.
1 4 . Turn the crankshaftcounterclockwiseto compress
the auto-lensioner,
1 7 . R e m o v et h e c a m c h a i ng u i d eB .
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t5.
Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e na 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe Din.
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a
\-
6 -14
CamChainInstallation
1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r
a r m( B ) .
t./6. | \
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NOTE:Keepthe cam chain away from magneticfields.
1. Set the crankshaftto top dead center(TDC).Align
the TDC mark {A) on the crankshaftsprocketwith
t h e p o i n t e r( B )o n t h e c y l i n d e rb l o c k .
g"'1 9 . R e m o v et h e c a m c h a i n .
t
Setthe camshaftsto TDC.The punch mark (A) on
the variablevalve timing control {VTC)actuatorand
t h e p u n c hm a r k( B )o n t h e e x h a u s ct a m s h a f t
sprocketshould be at the top. Align the TDC marks
(C)on the VTC actuatorand exhaustcamshaft
sprocKet.
(cont'd)
6-15
GylinderHead
CamChainInstallation(cont'dl
3. Installthecamchainon the crankshaft
sprocket
with thecoloredpiece(A)alignedwiththe punch
mark(B)on the crankshaft
sprocket.
\
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5 . I n s t a l l t h ec a m c h a i ng u i d eA ( A )a n d t e n s i o n ear r m
(B).
6x1.0mm
1 2N . m
{1,2kgf.m,
8.7 tbf.ftt
'6I
8 x 1 . 2 5m m
22 N.m
12.2kgt.m,
16tbf.ft)
Installthecam chain on the VTCactuatorand
exhaustcamshaftsprocketwith the punch marks
(A) alignedwith the two colored pieces(B).
B
6. Installthe auto-tensi
a
6x1,0mm
12Nm
(1.2kgt.m,8.7 lbf ti)
a
6-16
1 0 .Removeold liquid gasketfrom the chain case
7 , I n s t a ltlh e c a m c h a i ng u i d eB .
8 x 1.25mm
22 N.m
(2.2kgf.m,16lbt.ft)
H4
\ilt
H g
mating surfaces,bolts,and bolt holes.
1 1 .Cleanand dry the chain case mating surfaces.
evenlyto the
Apply liquid gasket.P/N 08718-0009,
cylinder block mating surfaceofthe chain caseand
t o t h e i n n e rt h r e a d so f t h e h o l e s .
q
8. Removethe Dinfrom the auto-tensioner,
Apply liquid gasket
alongthe brokenline.
Apply liquid gasketto the cylinder blockupper
surfacecontactareas(A) on the chaincase.
evenlyto the
1 4 . Apply liquid gasket,PiN 08718-0009,
oil pan mating surfaceof the chain caseand to the
innerthreadsof the holes.
9 . Checkthe chain caseoil sealfor damage.lf the oil
seal is damaged,replacethe chain case oil seal
( s e ep a g e6 - 2 1 ) .
NOTE:Do not installthe parts it 5 minutesor more
have elapsedsinceapplying liquid gasket.lnstead,
reapplyliquid gasketafter removing old residue.
Apply liquid gasket
alongthe brokenline.
(cont'd)
6-17
GylinderHead
CamChainInstallation(cont'd)
'15.
Installthe new O-ring(A) on the chain case.Set the
edge of the chain case (B)to the edge of the oil pan
( C ) ,t h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e rb l o c k
(D).
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1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .
NOTE:When installingthe chain case,do not slide
the bottom surfaceon the oil pan mounting surface.
rbf.ft)
',.9
17. Installthe upper bracket(A),then tightenthe bolv
nuts in the numberedseouenceshown.
6 x 1 . 0m m
12 N.m
{1.2kgl m, 8.7 lbf ft}
6x1.0mm
1 2N . m
(1.2kgt.m.8.7lbf.ft)
6x1.0mm
12Nm
(1.2kgf.m,8.7lbf.ft)
1 2 x 1 . 2m
5m
54 N.m
(5.5 kgt m, 40 lbf.ft)
\
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-TensionerRemovaU
lnstallation
1 9 . lnstallthe variablevalve timing control (VTC)oil
c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .
Removal:
20. Connectthe crankshaftposition(CKP)sensor
connector{A) and VTC oil control solenoidvalve
connector(B).
21. Installthe crankshaftpulley (seepage 6-12).
1 . R e m o v et h e c h a i nc a s ec o v e r .
Turn the crankshaftcounterclockwiseto compress
the auto-tensroner.
2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
2 3 . I n s t a l l t h ed r i v eb e l t .
2 4 . I n s t a l l t h es p l a s hs h i e l d .
€D@
{cont'd)
6-19
GylinderHead
Auto-TensionerRemoval/lnstallation(cont'dl
3. Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe oin.
4. Removethe auto-tensioner.
\
Installation:
1. Installthe auto-tensioner.
6x1.0mm
12 N.m {1.2kgt.m,8.7 lbt.tt)
Remove the pin from the auto-tensioner.
a
\
\-
6-20
ChainCaseOil SealInstallation
Removeold liquid gasketfrom the chain casecover
mating surfaces,bolts,and bolt holes.
SpecialToolsRequired
. Driver07749-0010000
. Attachment,52 x 55 mm 07746-0010400
4 . Cleanand dry the chain casecover mating surfaces.
Apply liquid gasket,P/N 08718-0009,
evenlyto the
chain case mating surfaceof the chain casecover
and to the innerthreadsof the holes.
NOTE:Do not installthe parts if 5 minutesor more
have elapsedsinceapplyingliquid gasket.Instead,
reapplyliquid gasketafter removing old residue.
Apply liquid gasket
a l o n gt h e b r o k e nl i n e .
1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l
squarelyinto the chain caseto the specified
i n s t a l l e dh e i g h t .
07749-0010000
2. Measurethe distancebetweenthe chain case
s u r f a c e( A )a n d o i l s e a l1 B ) .
6 . I n s t a l l t h ec h a i nc a s ec o v e r .
Oil Seal InstalledHeight:
3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )
6x1.0mm
1 2N . m
{1.2kgt.m,
8.7 tbf.ft)
33.0 33.7mm
{ 1 . 3 0 1 . 3 3i n . l
6-21
GylinderHead
CylinderHeadCoverRemoval
1. Removethe intakemanifoldcover.
(
\
4, Removethe cylinder headcover
V:t :;t 1
|,'.i/
2. Removethe four ignition coils (seepage 4-'18).
3. Removethe dipstick(A) and breatherhose (B).
(
\-
6-22
GylinderHeadRemoval
NOTE:
. Usefendercoversto avoiddamagingpainted
surfaces.
To avoid damage,unplug the wiring connectors
carefullywhlle holdingthe connectorportion.
To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100'F(38"C)
betore looseningthe cylinder head bolts.
Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
' 1 .Drainthe
8. Removethe enginewire harnessconnectorsand
wire harnessclampsfrom the cylinder head.
. Enginecoolanttemperature(ECT)sensor
conneclor
. Camshaftposition(Cl\4P)(top dead center(TDC))
sensor B connector
. Camshaftposilion (CMP)sensorA connector
9. Removethe upper radiatorhose (A) and heater
h o s e( B ) .
enginecoolant(seepage 10-6).
2 . Removethe drive belt (seepage 4-26).
3 . Removethe intakemanifold {seepage 9-3).
Removethe air cleanerhousing(seestep 7 on page
5-2t.
5. Removethe water bypasshose (A).
'10.
Removethe harnessholder (A)from the bracket,
then removethe connectingpipe mounting boh {B)
and brakeboostervacuum line mounting bolts {C).
6 . Removethe exhaustmanifold (seepage9-7) .
7 . Removethe cam chain (seepage 6-12).
11. Removethe water bvpasshose (D).
(cont'd)
6-23
CylinderHead
CylinderHeadRemoval(cont'd)
VTCActuator,ExhaustCamshaft
\
SprocketReplacement
Removethe rockerarm assembly(seepage 6-26).
tJ.
Removethe cylinderhead bolts.To prevent
warpage,unscrewthe bolts in sequence1/3turn at
a t i m e ; r e p e a t h e s e q u e n c eu n t i la l l b o l t sa r e
loosened.
CYLINDERHEADBOLTSLOOSENINGSEQUENGE:
Removal:
1 . R e m o v et h e c a m c h a i n( s e ep a g e6 - 1 2 ) .
2. Hold the camshaftwith an open-endwrench,then
loosenthe variablevalve timing control (VTC)
actuatormounting bolt and exhaustcamshaft
sprocketmounting bolt.
1 4 . R e m o v et h e c y l i n d e rh e a d .
I
\
(
Removethe VTC actuatorand exhaustcamshaft
sprocket.
I
6-24
Installation:
1. Installthe VTC actuatorand exhaustcamshaft
sprocket.
CylinderHeadInspectionfor
Warpage
1 , Removethe cylinder head{see page 6-23).
Inspectthe camshaft(seepage 6-29).
2. Apply engineoil to the th readsof the VTC actuator
mounting bolt and exhaustcamshaftmounting bolt,
then installthem.
3. Hold the camshaftwith an open-endwrench,then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
1 1 3N . m ( 1 1 . 5k g l . m , 8 3l b l . f t )
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
Checkthe cylinder headfor warpage.Measure
along the edges,and three ways acrossthe center.
. lf warpage is lessthan 0.05mm (0.002in.)
cylinder head resurfacingis not required.
. lf warpage is between0.05 mm (0.002in.) and
0.2 mm (0.008in.),resurfacethe cylinder head.
. Maximum resurfacelimit is 0.2 mm (0.008in,)
basedon a height of 104mm (4.09in.).
Cylinder Head Height;
Standard{New}: 103.95 104.05mm
{4.093 4.096in.}
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1.
Removethe cam chain (seepage 6-12).
4 . Removethe cam chain guide B, camshaftholders,
and camshafts.
2 . Loosenthe rockerarm adjustingscrews (A),
A
5 . Insertthe bolts (A) Into the rockershaft holder,then
removethe rockerarm assembly(B).
3. Removethe camshaftholder bolts.To Drevent
damagingthe camshafts,unscrewthe bolts two
turns at a time, in a crisscrosspattern.
CAMSHAFTHOLDERBOLTS LOOSENING
SEOUENCE:
\-
6-26
{
RockerArms and ShaftsDisassembly/Reassembly
NOTE:
ldentifypartsas they are removedto ensurereinstallationin original location.
Inspectthe rockershaftsand rockerarms (seepage 6-28).
The rockerarms must be installedin the same positionsif reused.
When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep
the holders,springsand rockerarms on the shaft.
Priorto reassembling,cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints.
Bundlethe rockerarms with rubber bandsto keeDthem tooetheras a set.
EXHAUSTROCKER
SHAFT
EXHAUSTROCKER
ARM
wASHEB
Yr
rY
Y
V
rffin
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\nl I ltnrllln
IJI_J;-L,JLI
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70)
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o
INTAKE ROCKER
ARM ASSEMBLY
INTAKEROCKERSHAFT
6-27
CylinderHead
RockerArms and ShaftsInspection
1 . Removethe rockerarm assembly(seepage 6-26).
2 . Measurethe diameterof the shaft at the first rocker
location.
\
4. Measurethe insidediameterofthe rockerarm, and
checkit for an out-of-roundcondition.
Rocker Arm-to-Shaflt Clearance:
Standard lNew):
0.025 0.052 mm
lntake:
(0.0010 0.0020in.)
Exhaust:
0.018 0.056mm
(0.0007 0.0022in.)
0.08 mm (0.003in.)
Service Limit:
3. Zero the gauge (A)to the shaft diameter.
5. Repeatfor all rockerarms and both shafts.lfthe
clearanceis over the Ilmit. replacethe rockershaft
and all overtolerancerockerarms. lf any VTEC
rockerarm needs replacement,replacethe rocker
arms (primaryand secondary)as a set.
(
\.
6. Inspectthe rockerarm pistons{A}.Pusheach
p i s t o nm a n u a l l y .
lf it does not move smoothly,replacethe rocker
arm set.
NOTE:Apply oil to the pistonswhen reassembling.
,,,@@
(
6-28
GamshaftInspection
NOTE:Do not rotatethe camshaftduring inspection.
1. Removethe rockerarm assembly(seepage 6-26).
and disassembleit (seepage6-27).
2. Putthe rockershaft holders,camshaft,and
camshaftholderson the cylinderhead,then tighten
the bolts to the specifiedtorque.
Specified torque:
I mm bolis:
22 N.m {2.2kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2kgf.m,8.7 tbf.ftl
6 mm bolts: @, €0, @
3. Seatthe camshaftby pushing it away from the
camshafp
t u l l e ye n d o f t h e c y l i n d e rh e a d .
4. Zero the dial indicatoragainstthe end of the
camshaft,then push the camshaftbackand forth
and read the end play. lf the end play is beyondthe
servicelimit, replacethe camshafthead and
recheck.lf it is still beyondthe servicelimit, replace
thecylinder.
CamshaftEnd Play:
Standard{New}:0.05 0.20 mm
(0.002 0.008in.l
ServiceLimit: 0.4 mm (0.02in.)
I
I
(cont'd)
6-29
CylinderHead
CamshaftInspection(cont'dl
Unscrewthe camshaftholder boltstwo turns at a
time, in a crisscrosspattern.Then removethe
camshaftholdersfrom the cylinder head.
Lift the camshaftsout of the cylinder head,wipe
them clean.then inspectthe lift ramps.Replacethe
camshaftif any lobes are pitted,scored,or
excessivelyworn,
1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r
head,then set the camshaftsbackin place.Placea
plastigagestrip acrosseachjournal.
Installthe camshaftholders,then tighten the bolts
to the specifiedtorque as shown in step 2.
\
{
\,
I
10. Checkthe total runoutwith the camshaftsupported
on V-blocks,
. l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e
servicelimit, replacethe cylinder head.
. lf the total runout is beyondthe servicelimit,
replacethe camshaftand recheckthe camshaftto-holderoil clearance.lf the oil clearanceis still
beyondthe servicelimit, replacethe cylinder
neao.
Camshaft Total Runout:
Standard(New):0.03mm (0.001in.) max.
ServiceLimit: 0.04mm {0.002in.)
9 . Removethe camshaftholders.Measurethe widest
portionof plastigageon eachjournal.
. lf the camshaft-to-holder
clearanceis within
l i m i t s ,g o t o s t e p 11 .
. lf the camshaft-to-holder
clearanceis beyondthe
servicelimit and the camshafthas been replaced,
replacethe cylinder head.
. lf the camshaft-to-holder
clearanceis beyondthe
servicelimit and the camshafthas not been
replaced,go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
0.030 0.069mm
No.2,3,4,5 Journals:
ServiceLimit:
{0.001 0.003in-)
0.060*0.099mm
{0.002 0.004in.)
0 . 1 5m m { 0 . 0 0i6n . )
1 1 . M e a s u r ec a m l o b eh e i g h t .
Cam Lobe HeiohtStandard(New
INTAKE
PRI
3 3 . 9 2 5m m
(1.3356
in.)
2 9 . 6 3m
8m
( 1 . 1 6 6i n8 . )
P R IP
: rimary
C/C:CamChain
EXHAUST
34.092mm
\1.3422in.l
SEC
SEC:Secondary
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired
Valvespring compressorattachment07VAE-001010A
4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .
ldentifythe valvesand valve springsas they are
removedso that each item can be reinstalledin its
original position.
1. Removethe cylinder head (seepage 6-23).
2. Using an appropriate-sized
socket(A) and plastic
mallet {B),lightly tap the valve retainerto loosen
the valve keepers.
5 . Removet h e v a l v es e a l .
\
Installthe spring compressor.Compressthe spring,
and removelhe valve keepers.
6-31
GylinderHead
ValveInspection
ValveStem-to-GuideClearance
Inspection
\
1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,
2 . Measurethe valve in these areas.
lntake Valve Dimensions
A StandardlNewl: 34.85 35.15mm
{ 1 . 3 7 2 1 . 3 8 4i n . l
B Standard{Newl: 108.7- 109.5mm
14.280-4.311in.)
C StandardlNew): 5.475 5.485 mm
1 0 . 2 1 5 6 - 0 . 2 1 5i n9 . )
C ServiceLimit:
5.445mm {0.214in.l
ExhaustValve Dimensions
A Standard(New):29.85-30.15 mm
( 1 . 1 7 5 -1 . 1 8 7i n . )
B Standard(New):108.3 109.1mm
(4.264- 4.295 in.l
C Standard(New):5.450 5.460mm
(0.2146 0.2150in.)
C ServiceLimit: 5.42mm (0.213in.)
1 . Removethe valves (seepage6-3'1).
S l i d et h e v a l v eo u t o f i t s g u i d ea b o u t1 0 m m . t h e n
measurethe guide-to-stemclearancewith a dial
indicatorwhile rockingthe stem in the directionof
normal thrust (wobble method).
. l f t h e m e a s u r e m e net x c e e d s t h es e r v i c el i m i t ,
recheckit using a new valve.
. lf the measurementis nowwithin the service
limit, reassembleusing a new valve.
. l f t h e m e a s u r e m e n t w i ta
h n e w v a l v es t i l l
exceedsthe servicelimit, go to step 3.
lntake Valve Stem-to-Guide Clearance:
StandardlNew): 0.06 0.11 mm
{0.002 0.004in.}
ServiceLimil: 0.16mm {0.006in.)
Exhaust Valve Stem-to-Guide Clearance:
S t a n d a r dl N e w l : 0 . 1 1- 0 . 1 6 m m
10.004 0.006in.)
ServiceLimit: 0.22 mm 10.009in.)
.<
4,.
(
3 . Subtractthe O.D.of the valve stem. measuredwith
a micrometer,from the LD. of the valve guide,
m e a s u r e dw i t h a n i n s i d em i c r o m e t eor r b a l lg a u g e .
Takethe measurementsin three placesalong the
v a l v es t e m a n dt h r e ep l a c e si n s i d et h e v a l v eg u i d e .
The differencebetweenthe largestguide
m e a s u r e m e nat n dt h e s m a l l e s st t e m m e a s u r e m e n t
should not exceedthe servicelimit
lntake Valve Stem-to-GuideClearance:
Standard(New):0.030 0.055mm
{0.0012 0.0022in.)
ServiceLimit; 0.08mm (0.003in.l
ExhaustValve Stem-to-GuideClearance:
Standard{Newl: 0.055 0.080mm
(0.0022-0.003rin.l
ServiceLimit: 0.11mm (0.004in.)
6-32
t-
I
ValveGuideReplacement
SpecialToolsRequired
. Valveguidedriver,5.5mm 07742-0010100
. Valveguidereamer,5.5mm 07HAH-PJ7o108
1 . Inspectvalve stem-to-guideclearance(seepage 6-
32t.
As illustratedbelow, use a commerciallyavailable
air-impactvalve guide driver (A) modifiedto fit the
diameterof the valve guides.In most cases,the
same procedurecan be done usingthe specialtool
and a conventionalhammer.
Working from the camshaftside. usethe driver and
an aarhammerto drive the guide about 2 mm (0.1
in.)towardsthe combustionchamber.This will
knockoff some of the carbon and make removal
easier.Hold the air hammer directlyin line with the
valve guide to preventdamagingthe driver.
Turn lhe head over, and drive the guide out toward
the camshaftside of the head.
tT
-_|Jfillr-.-4fi'11.,
10.8mm
{0.,|2in.)
3. Selectthe proper replacementguides,and chill
lhem in the freezersectionof a refriqeratorfor
about an hour.
4. Use a hot plate or oven to evenly heatthe cylinder
headto 300'F (150"C).Monitor the temperature
with a cookingthermometer.Do not getthe head
hotterthan 300'F (150"C);excessiveheat may
loosenthe valve seats.
7 . lf a valve guide won't move, drill it out with a I mm
( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n
extremecases;youcould damagethe cylinder
head if the guide breaks.
Removethe new guide(s)from the freezer,one at a
time, as vou needthem.
(cont'd)
6-33
CylinderHead
ValveGuideReplacement(cont'dl
Apply a thin coat of clean engineoil to the outside
of the new valve guide. Installthe guide from the
camshaftside of the head;usethe specialtool to
drive the guide in to the specifiedinstalledheight
( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o ,
you may have to reheatthe head.
\
1 0 .Coat both reamerand valve guide with cutting oil.
1 1 .Rotatethe reamerclockwisethe full length of the
v a l v eg u i d eb o r e .
O7HAH.PJ7O1OB
Valve Guide Installed Height:
15.2 16.2mm (0.598-0.638in.)
Intake:
Exhaust: 15.5 16.5mm (0.610-0.650in.)
' - \
Continueto rotatethe reamerclockwisewhile
removing it from the bore.
Thoroughlywash the guide in detergentand water
to remove any cutting residue.
1 4 . C h e c kt h e c l e a r a n c ew
s i t h a v a l v e( s e ep a g e6 3 2 ) .
Verifythat a valve slidesin the intakeand exhaust
valve guideswithout exening pressure.
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guideclearance(seepage 632).lf the valve guidesare worn, replacethem (see
page6-33)beforecuttingthe valve seats.
2 . R e n e wt h e v a l v es e a t si n t h e c y l i n d e rh e a du s i n ga
valve seat cutter.
5. Make one more very light passwith the 45" cutter
to removeany possibleburrs causedby the other
cutters.
Valve Seat Width:
Standard(New): 1.25 1.55mm {0.049 0.061in.)
ServiceLimit: 2.00 mm (0.079in.)
6. After resurfacingthe seat,inspectfor even valve
s e a t i n gA: p p l y P r u s s i a nB l u ec o m p o u n d( A )t o t h e
v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o ni n
the head,then lift it and snap it closedagainstthe
seat severaltrmes.
3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h
materialto ensurea smooth and concentricseat.
4 . Bevelthe upper and lower edgesat the angles
shown in the illustration.
Checkthe width of the seat and adjustaccordingly.
INTAKE:35"
EXHAUST:30'
- 45'
, { 67.5'
1 . The actualvalve seatingsurface(B),as shown by
the blue compound,should be centeredon the seat.
. lf it is too high (closerto the valve stem),you
must make a secondcut with the 67.5' cutterto
move it down, then one more cut with the 45"
cutterto restoreseatwidth.
. lf it is too low (closeto the valve edge),you must
make a secondcut with the 35'cutter (intake
sidel or the 30" cutter (exhaustside)to move it up,
then make one more cut with the 45" cutterto
restoreseatwidth.
N O T ET
: h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h
the 45'cutter.
(cont'd)
6-35
CylinderHead
ValveSeat Reconditioning(cont'dl
(
\
8 . Insen the intakeand exhaustvalves in the head,
and measurevalve stem installedheight (A).
Intake Valve Stem Installed Height:
Standard{New):40.8 41.0mm
( 1 . 6 0 6 1 . 6 1 4i n . )
Exhaust Valve Stem Installed Height:
Standard(New):54.6-54.8 mm
|'2.150-2.157 in.l
L lf valve stem installedheight is over the standard,
replacethe valve and recheck.lf it is still over the
standard,replacethe cylinder head;the valve seat
in the head is too deeD.
\-
\-
6-36
Valves,Springs,and Valve SealsInstallation
Special Tools Required
Valve spring compressorattachment07VAE-00101
0A
1. Coatthe valve stemswith engine oil. lnstallthe
valves in the valve guides.
2. Checkthat the valves move up and down smoothly.
Installthespring seatson the cylinder head.
l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e
spring with closelywound coils toward the cylinder
ne a o .
6 . Installthe valve retainer.
7 . Installthevalve spring compressor,Compressthe
spring, and installthe valve keepers.Removethe
valve spring compressor.
Installthe new valve seals(A) usingthe valve guide
s e a li n s t a l l e(rB ) .
NOTE:The exhaustvalve seal (C)has a blackspring
(D),and the intakevalve seal (E)has a white spring
(F).They are not interchangeable.
Lightlytap the end of each valve stem two or three
times with a plasticmallet (A)to ensureproper
seatingof the valve and valve keepers.Tap the
valve stem only along its axis so you do not bend
the stem.
6-37
CylinderHead
RockerArm AssemblyInstallation
:,ean and dry the No. 5 rockershaft holder mating
surfaces.
\
5 . Removethe bolts from the rockershaft holder.
6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e
eeassemblethe rockerarm assembly(seepage 62 1t .
Apply liquid gasket,P/N 08718-0009,
evenlyto the
:ylinder head mating surfaceofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstallthe partsif 5 minutesor more
r a v e e l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e tI.n s t e a d ,
'eapply liquid gasketafter removingold residue.
timing control (VTC)actuatorand exhaustcamshaft
sprocketare facing up. then set the camshafts(A) in
the holder.
fl
c
I
Apply liquid gasket
alongthe brokenline.
Insertthe bolts (A) into the rockershaft holder,then
installthe rockerarm assembly(B)on the cylinder
head.
a
\7 . Set the camshaftholders(B) and cam chain guide B
( C )i n p l a c e .
Tightenthe bolts to the specifiedtorque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstallthe cam chain (seepage 6-15).and adjustthe
valve clearance(seepage 6-9).
6-38
l-
{
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of
removat:
5. Measurethe diameterof each cylinder head bolt at
ooint A and DointB.
a 50mm (2.0in.l
1. Cleanthe cylinderhead and blocksurface.
f.f
2. Installthe new cylinder headgasket(A) anddowel
pins (B)on the cylinderblock.Always use a new
cylinder headgasket.
)>-
A '15mm {'1.8in.)
" < > .
l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) ,
replacethe cvlinder head bolt.
Set the crankshaftto top dead center{TDC).Align
the TDC mark (A) on the crankshaftsprocketwith
the pointer(B)on the cylinderblock.
4. Installthe cylinderhead on the block.
( c o n td )
6-39
CylinderHead
CylinderHeadlnstallation(cont'd)
7 . Apply engine oil to the bolt threadsand under the
b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .
8 . Tightenthe cylinder head bolts in sequenceto 39
\
{
10. Installthe rockerarm assembly{seepage6-38).
1 ' .t Installthe water bypasshose (A).
N.m {4.0 kgf.m,29 lbf.ft).Use a beam-typetorque
wrench.When using a preset-typetorque wrench,
be sure to tighten slowly and do not overtighten.lf
a bolt makesany noisewhile you are torquing it,
loosenthe bolt and retightenit from the first step.
---l.-.
B
6
x1.0mm
'r2
N.m
c
(1.2kgl.m,8.7lbf.ftl
6
x
l
.
0
m
m
'12N,m(1.2kgt.m,8.7
lbf.ft)
9 . After torquing,tighten all cylinderhead bolts in two
steps(90" per step).lf you are using a new cylinder
head bolt,tighten the bolt an extra 90..
1 2 .Tightenthe connectingpipe mounting bolt (B)and
brakeboostervacuum line mounting bolts (C),then
i n s t a l l t h eh a r n e s sh o l d e r( D )o n t h e b r a c k e t .
't3. Installthe
(B).
upper radiatorhose {A) and heaterhose
FIRSTSTEP
SECOND
STEP
v
6-40
GylinderHeadCoverlnstallation
1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e .
1. Thoroughlycleanthe headcover gasketand the
groove.
2. Installthe head cover gasket(A) in the groove of
t h e c y l i n d e rh e a dc o v e r( B ) .
1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) .
1 7 . I n s t a l l t h ee x h a u s tm a n i f o l d( s e ep a g e9 - 7 ) .
Checkthat the mating surfacesare clean and dry.
'18.
I n s t a l l t h ec a m c h a i n ( s e ep a g e6 - 1 5 ) .
on the chain
Apply liquid gasket.P/N 08718-0009,
caseand the No.5 rockershaft holder mating areas.
1 9 . A d j u s tt h e v a l v ec l e a r a n c e( s e e p a g e 6 - 9 ) .
2 0 . I n s t a l l t h ed r i v eb e l t( s e ep a g e4 - 2 6 ) .
NOTE:Do not installthe parts if 5 minutesor more
have elapsedsinceapplying liquid gasket.Instead,
reapplyliquid gasketafter removing old residue.
21. Cleanthe batterypostsand cableterminalswith
s a n d p a p e rt h
, e n a s s e m b l et h e m a n d a p p l yg r e a s e
to preventcorrosion.
2 2 . A f t e ri n s t a l l a t i o nc ,h e c k t h a t a ltl u b e s ,h o s e s a n d
connectorsare installedcorrectly.
. u r nt h e i g n i t i o ns w i t c hO N
2 3 . I n s p e c t f o r f u elle a k sT
{ll) {do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthls operationtwo or three times, then
c h e c kf o r f u e l l e a k a g ea t a n y p o i n ti n t h e f u e l l i n e .
24. Refillthe radiatorwith enginecoolant,and bleed
air from the cooling systemwith the heatervalve
open (seepage 10-6).
2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) .
2 6 . I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
(cont'd)
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GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes.
O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r
head,slide the cover slightly backand forth to seat
the head cover gasket.
7. Tightenthe bolts in two or three steps.In the final
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 9 . 8 N . m ( 1 . 0
kgf.m,7.2 lbf.ft).
8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .
Inspectthe cover washers(C).Replaceany washer
that is damagedor deteriorated.
\
\l
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9 . Installthe four ignition coils (seepage 4-'18).
1 0 . Checkthat all tubes, hoses,and connectorsare
installedcorrectly.
1 1 .lnstallthe intakemanifoldcover.
6
x 1 , 0m m
'12
N.m{1.2kgf m.
8.7tbf.ftl
12. After assemblv,wait at least30 minutesbefore
f i l l i n gt h e e n g i n ew i t h o i l .
6-43