Cylinder Head Acura RSX I

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Engine Compression Inspection

Note. On the 2005-2006 models: After this inspection, you must reset the engine control module (ECM)/powertrain control module (PCM), otherwise ECM/PCM will continue to stop the injectors from functioning. Select ECM/PCM reset using the Honda Diagnostic System (HDS) (see ECM/PCM RESET (2002-2004 MODELS) ).

Scheme 65

1. Warm up the engine to normal operating temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. 2002-2004 models: Remove the No. 17 (15 A) fuse from the under-dash fuse/relay box. 2005-2006 models: Connect the HDS to the data link connector (DLC) (see step 2 on «IF THE MIL (MALFUNCTION INDICATOR LAMP) HAS COME ON»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems) ). Turn the ignition switch ON (II), then select PGM-FI, INSPECTION, then All INJECTORS OFF function on the HDS.
4. Remove the four ignition coils (see «IGNITION COIL REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/ignition-system/#ignition-system) ).
5. Remove the four spark plugs.
6. Attach the compression gauge to the spark plug hole.
7. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure: Above 930 kPa (9.5 kgf/cm 2 ,135 psi)
8. Measure the compression on the remaining cylinders. Maximum Variation: Within 200 kPa (2.0 kgf/cm 2 ,28 psi)
9. 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
10. Remove the compression gauge from the spark plug hole.
11. Install the four spark plugs.
12. Install the four ignition coils (see «IGNITION COIL REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/ignition-system/#ignition-system) ).
13. 2002-2004 models: Install the No. 17 (15 A) fuse from the under-dash fuse/relay box. 2005-2006 models: Select ECM/PCM reset (see «ECM/PCM RESET (2002-2004 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__ecmpcm-reset-2002-2004-models) ) to stop the ALL INJECTORS OFF function on the HDS.

VTEC Rocker Arm Test

Special Tools Required

1. Air pressure regulator 07AAJ-PNAA100
2. VTEC air adapter 07ZAJ-PNAA100
3. VTEC air stopper 07ZAJ-PNAA200
4. Air joint adapter 07ZAJ-PNAA300

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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»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
3. Set the No. 1 piston at top dead center (TDC) (see step 1 ).
4. Verify that the intake primary rocker arm (A) moves independently of the intake secondary rocker arm (B). If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly, and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. If the intake primary rocker arm moves freely, go to step 4 .
5. Repeat step 3 on the remaining intake primary rocker arms with each piston at TDC. When all the primary rocker arms pass the test, go to step 5.
6. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4.0 kgf/cm 2 , 57 psi).
7. Inspect the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-clearance-adjustment) ).
8. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B).
9. Remove the No. 2 and 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/cm 2 ,42 psi) NOTE: If the synchronizing piston does not move after applying air pressure; move the primary or secondary rocker arm up and down manually by rotating the crankshaft clockwise.
12. With the specified air pressure applied, move the intake primary rocker arm (A) for the No. 1 cylinder. The primary rocker arm and secondary rocker arm (B) should move together. If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly, and check that the pistons in the primary and secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test.
13. Remove the special tools.
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, 14 lbf.ft).
16. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).

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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»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
3. Set the No. 1 piston at TDC (see step 1 ).
4. Move the secondary rocker arm (A) for 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 4 .
5. Repeat step 3 on the remaining secondary rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 5.
6. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4.0 kgf/cm 2 , 57 psi).
7. Inspect the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-clearance-adjustment) ).
8. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B).
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/cm 2 ,42 psi) NOTE: If the synchronizing piston does not move after applying air pressure; move the rocker arm up and down manually by rotating the crankshaft.
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.
13. Remove the special tools.
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, 14 lbf.ft).
16. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).

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1. Remove the cam chain (see «CAM CHAIN REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-removal) ).
2. Loosen the rocker arm adjusting screws (see step 2 ).
3. Remove the camshaft holder (see step 3 ).
4. Remove the intake camshaft.
5. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator.
6. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with the tape.
7. Punch a hole in the tape over one of the advance holes.
8. Apply air to the advance hole to release the lock.
9. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator.
10. 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 ).
11. Set the camshaft holders and chain guide B in place (see step 7 ).
12. Tighten the camshaft holder bolts to the specified torque (see step 8 ).
13. 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.
14. Install the cam chain (see «CAM CHAIN INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-installation) ).
15. Adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-clearance-adjustment) ).

Valve Clearance Adjustment

Special Tools Required

1. Tappet adjust wrench set 07MAA-PR70100

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

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1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Set the No. 1 piston at TDC. The punch mark (A) marked with an arrow 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.
3. Select the correct thickness feeler gauge for the valves you're going to check. Valve Clearance K20A3 Engine: Intake: 0.21-0.25 mm (0.008-0.010 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) K20A2, K20Z1 Engines: Intake: 0.21-0.25 mm (0.008-0.010 in.) Exhaust: 0.25-0.29 mm (0.010-0.011 in.)
4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag.
5. If you feel too much or too little drag, loosen the locknut with the special tools, and turn the adjusting screw until the drag on the feeler gauge is correct.
6. Tighten the locknut to the specified torque. Specified Torque K20A3 Engine: Intake: 20 N.m (2.0 kgf.m, 14 lbf.ft) Apply engine oil to the nut threads. Exhaust: 14 Nm (1.4 kgf.m, l0 lbf.ft) K20A2, K20Z1 Engines: 20 N.m (2.0 kgf.m, 14 lbf.ft) Apply engine oil to the nut threads.
7. Recheck the valve clearance. Repeat the adjustment if necessary.
8. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).
9. Check and, if necessary, adjust the valve clearance on No. 3 cylinder.
10. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).
11. Check and, if necessary, adjust the valve clearance on No. 4 cylinder.
12. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°).
13. Check and, if necessary, adjust the valve clearance on No. 2 cylinder.
14. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).

Crankshaft Pulley Removal and Installation

Special Tools Required

1. Holder handle 07JAB-001020A
2. Holder attachment, 50 mm 07NAB-001040A
3. Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

Scheme 82

Scheme 83

1. Remove right front wheel.
2. Remove the splash shield.
3. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
4. Hold the pulley with holder handle (A) and holder attachment (B).
5. Remove the bolt with a 19 mm socket (C) and breaker bar.

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Scheme 85

1. Clean the crankshaft pulley (A), crankshaft (B), bolt (C), and washer (D). Lubricate with new engine oil as shown.
2. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B).
3. Tighten the bolt to 49 N.m (5.0 kgf.m, 36 lbf.ft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench.
4. Tighten the pulley bolt an additional 90°.
5. Install the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
6. Install the splash shield (see step 25 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
7. Install right front wheel.

Cam Chain Removal

Special Tools Required

1. Holder handle 07JAB-001020A
2. Holder attachment, 50 mm 07NAB-001040A
3. Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

Note. Keep the cam chain away from magnetic fields.

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1. Turn the crankshaft pulley so its TDC mark (A) lines up with the pointer (B).
2. Remove the right front wheel.
3. Remove the splash shield.
4. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
5. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
6. Check that the No. 1 piston TDC marks (A) on the variable valve timing control (VTC) actuator and exhaust camshaft sprocket are aligned.
7. Hold the pulley with holder handle (A) and holder attachment (B).
8. Remove the bolt with a 19 mm socket (C) and breaker bar.
9. K20A2, K20Z1 engines: Remove the oil cooler hose joint pipe from the water pump.
10. Disconnect the CKP sensor connector (A) and VTC oil control solenoid valve connector (B).
11. Remove the VTC oil control solenoid valve (see «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
12. Support the engine with a jack and wood block under the oil pan.
13. Remove the ground cable (A), and remove the upper bracket (B).
14. Remove the side engine mount bracket.
15. Remove the chain case.
16. Loosely install the crankshaft pulley.
17. Turn the crankshaft counterclockwise to compress the auto-tensioner.
18. 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.
19. Remove the auto-tensioner.
20. Remove the cam chain guide B.
21. Remove the cam chain guide A and tensioner arm (B).
22. Remove the cam chain.

Cam Chain Installation

Special Tools Required

1. Holder handle 07JAB-001020A
2. Holder attachment, 50 mm 07NAB-001040A
3. Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

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.

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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.
2. Set the camshafts to TDC. The punch mark (A) marked with an arrow 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.
3. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the punch mark (B) on the crankshaft sprocket.
4. Install the cam chain on the VTC actuator and exhaust camshaft sprocket with the punch marks (A) aligned with the two colored pieces (B).
5. Install the cam chain guide A and tensioner arm (B).
6. Install the auto-tensioner.
7. Install the cam chain guide B.
8. Remove the pin or lock pin (P/N 14511-PNA-003) from the auto-tensioner.
9. 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»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__chain-case-oil-seal-installation) ).
10. Remove all of the old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
11. Clean and dry the chain case mating surfaces.
12. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002,08718-0003, or 08718-0009, evenly to the engine block mating surface on the chain case.
13. 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.
14. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0002,08718-0003 or 08718-0009, evenly to the oil pan mating surface of the chain case. NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
15. 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 the excess liquid gasket on the oil pan and chain case mating area. 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.
16. Install the side engine mount bracket.
17. Install the upper bracket (A), then tighten the bolt/nuts in the numbered sequence shown.
18. Install the ground cable (B).
19. Install the VTC oil control solenoid valve (see step 1 on «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
20. Connect the CKP sensor connector (A) and VTC oil control solenoid valve connector (B).
21. K20A2, K20Z1 engines: Install the oil cooler hose joint (A), using a new O-ring (B).
22. Clean the crankshaft pulley (A) and pulley bolt (B), and lubricate with new engine oil to the pulley bolt and washer (C).
23. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B).
24. Tighten the bolt to 49 N.m (5.0 kgf.m, 36 lbf.ft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench.
25. Tighten the pulley bolt an additional 90°.
26. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
27. Install the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
28. Install the splash shield.
29. Install the right front wheel.
30. 2005-2006 models: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see «ECM/PCM RESET (2005-2006 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__ecmpcm-reset-2005-2006-models) ).

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1. Remove the chain case cover.
2. Turn the crankshaft counterclockwise to compress the auto-tensioner.
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.
4. Remove the auto-tensioner.

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1. Install the auto-tensioner.
2. Remove the pin or lock pin (P/N 14511-PNA-003) from the auto-tensioner.
3. Remove all of the 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, 08718-0002,08718-0003, or 08718-0009, evenly to the chain case mating surface of the chain case. NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
6. Install the chain case cover. NOTE: 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 cover.

Chain Case Oil Seal Installation

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 52 x 55 mm 07746-0010400

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1. Use the special tools to drive a new oil seal squarely into the chain case to the specified installed height.
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.)

Scheme 127

1. Remove the front wheels.
2. Remove the splash shield.
3. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
4. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
5. Remove the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__crankshaft-pulley-removal-and-installation) ).
6. K20A2, K20Z1 engines: Remove the oil cooler hose joint pipe from the water pump (see step 9 ).
7. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector (see step 10 ).
8. Remove the VTC oil control solenoid valve (see «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
9. Support the engine with a jack and wood block under the oil pan.
10. Remove the ground cable, and remove the upper bracket (see step 13 ).
11. Remove the side engine mount bracket (see step 14 ).
12. Remove the chain case (see step 15 ).
13. Measure the tensioner rod length between the tensioner body and bottom of the flat surface section on the tensioner rod. If the length is over the tolerance, replace the cam chain and oil pump chain. Tensioner Rod Length Service Limit: 13.5 mm (0.53 in.)
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»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__chain-case-oil-seal-installation) ).
15. Remove all of the old liquid gasket from the chain case mating surfaces, bolt and bolt holes.
16. Clean and dry the chain case mating surfaces.
17. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002,08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case (see step 12 ).
18. Apply liquid gasket 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 13 ).
19. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002, 08718-0003 or 08718-0009, evenly to the oil pan mating surface of the chain case (see step 14 ). NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the 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 15 ). Wipe off the excess liquid gasket on the oil pan and chain case mating area. 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.
21. Install the side engine mount bracket (see step 16 ).
22. Install the upper bracket and the ground cable (see step 17 ).
23. Install the VTC oil control solenoid valve (see «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
24. Connect the CKP sensor connector and VTC oil control solenoid valve connector (see step 20 ).
25. K20A2, K20Z1 engines: Install the oil cooler hose joint, using a new O-ring (see step 21 ).
26. Install the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__crankshaft-pulley-removal-and-installation) ).
27. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
28. Install the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
29. Install the splash shield.
30. Install the front wheels.
31. 2005-2006 models: Do the CKP pattern clear/CKP learn procedure (see «ECM/PCM RESET (2005-2006 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__ecmpcm-reset-2005-2006-models) ).

Scheme 128

1. Remove the right front wheel.
2. Remove the splash shield.
3. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
4. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
5. Remove the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__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 10 ).
7. Remove the VTC oil control solenoid valve (see «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
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 13 ).
10. Remove the side engine mount bracket (see step 14 ).
11. Remove the chain case (see step 15 ).
12. Remove the CKP pulse plate.
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»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__chain-case-oil-seal-installation) ).
15. Remove all of the old liquid gasket from the chain case mating surfaces, bolt, and bolt holes.
16. Clean and dry the chain case mating surfaces.
17. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002,08718-0003 or 08718-0009, evenly to the engine block mating surface of the chain case (see step 12 ).
18. Apply liquid gasket 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 13 ).
19. Apply liquid gasket P/N 08717-0004,08718-0001, 08718-0002, 08718-0003 or 08718-0009, evenly to the oil pan mating surface of the chain case (see step 14 ). NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the 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. Wipe off the excess liquid gasket on the oil pan and chain case mating area (see step 15 ). NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.
21. Install the side engine mount bracket (see step 16 ).
22. Install the upper bracket and the ground cable (see step 17 ).
23. Install the VTC oil control solenoid valve (see «VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#vtecvtc) ).
24. Connect the CKP sensor connector and VTC oil control solenoid valve connector (see step 20 ).
25. Install the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__crankshaft-pulley-removal-and-installation) ).
26. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
27. Install the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
28. Install the splash shield (see step 28 ).
29. Install the right front wheel.
30. 2005-2006 models: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see «ECM/PCM RESET (2005-2006 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__ecmpcm-reset-2005-2006-models) ).

Scheme 129

Scheme 130

1. Remove the intake manifold cover (see step 1 on «REMOVAL - K20A3 ENGINE»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ).
2. Remove the four ignition coils (see «IGNITION COIL REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/ignition-system/#ignition-system) ).
3. Remove the bolt (A) securing the power steering hose bracket.
4. Remove the dipstick (B) and breather hose (C).
5. Remove the cylinder head cover.

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

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).
3. Check that the mating surfaces are clean and dry.
4. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002,08718-0003, or 08718-0009 on the chain case and the No. 5 rocker shaft holder mating areas. NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
5. Set the spark plug seals (A) on the spark plug tubes. Once the cylinder head cover (B) is on the cylinder head, slide the cover slightly back and forth to seat the head cover gasket.
6. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.
7. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft). NOTE: Wait at least 30 minutes before filling the engine with oil. Do not run the engine for at least 3 hours after installing the cylinder head.
8. Install the dipstick (A) and breather hose (B).
9. Tighten the bolt (C) securing the power steering hose bracket.
10. Install the four ignition coils (see «IGNITION COIL REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/ignition-system/#ignition-system) ).
11. Check that all tubes, hoses, and connectors are installed correctly.
12. Install the intake manifold cover.

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.

Scheme 137

Scheme 138

Scheme 139

Scheme 140

1. Relieve fuel pressure (see «FUEL PRESSURE RELIEVING»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-pressure-relieving) ).
2. Drain the engine coolant (see «COOLANT CHECK»(/acura/rsx/i-2001-2004/remont/cooling-system-mechanical/#cooling-system) ).
3. K20A3 engine: Remove the fuel feed line (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-linequick-connect-fitting-removal) ).
4. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
5. Remove the intake manifold: K20A3 engine (see «REMOVAL - K20A3 ENGINE»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ) K20A2, K20Z1 engines (see «REMOVAL - K20A2, K20Z1 ENGINES»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) )
6. Remove the water bypass hose (A).
7. Remove the exhaust manifold (see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ).
8. Remove the cam chain (see «CAM CHAIN REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-removal) ).
9. Remove the engine wire harness connectors and wire harness clamps from the cylinder head. Four injector connectors (K20A3 engine) Engine coolant temperature (ECT) sensor connector Camshaft position (CMP) sensor A connector (Intake side) Camshaft position (CMP) sensor B connector (Exhaust side)
10. Remove the upper radiator hose (A) and heater hose (B).
11. Remove the harness holder (A) from the bracket, then remove the connecting pipe mounting bolt (B) and water bypass line mounting bolts (C).
12. Remove the water bypass hose (D).
13. Remove the rocker arm assembly (see «ROCKER ARM ASSEMBLY REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
14. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
15. Remove the cylinder head.

Scheme 141

Scheme 142

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Hold the intake camshaft with an open-end wrench, then loosen the bolt.
3. Remove the camshaft position (CMP) pulse plate A.
4. Install the CMP pulse plate A in the reverse order of removal.

Scheme 143

Scheme 144

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Hold the exhaust camshaft with an open-end wrench, then loosen the bolt.
3. Remove the camshaft position (CMP) pulse plate B.
4. Install the CMP pulse plate B in the reverse order of removal.

Scheme 145

1. Remove the cam chain (see «CAM CHAIN REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__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.
3. To the VTC actuator reused, do the following 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 ). 2 Punch a hole in the tape over one of the advance holes (see step 7 ). 3 Apply air to the advance hole to release the lock (see step 8 ).
4. Remove the VTC actuator and exhaust camshaft sprocket.

Scheme 146

1. Install the VTC actuator and exhaust camshaft sprocket. NOTE: Install the VTC actuator in the unlock position.
2. Apply 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 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)
4. Hold the camshaft, and turn the VTC actuator clockwise until you hear it click.
5. Install the cam chain (see «CAM CHAIN INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-installation) ).

Scheme 147

1. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Inspect the camshaft (see «CAMSHAFT INSPECTION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__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.)

Scheme 148

Scheme 149

Scheme 150

1. Remove the cam chain (see «CAM CHAIN REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-removal) ).
2. Loosen the rocker arm adjusting screws (A).
3. Remove the camshaft holder bolts. To prevent damaging the camshafts, unscrew the bolts two turns at a time, in a crisscross pattern. NOTE: Bolt (1) is not on all engines.
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).

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 ). The rocker arms must be installed in the same positions if reused. When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs, and rocker arms on the shaft. Prior to reassembling, clean all the parts in solvent, 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 VTEC rocker arm assembly, remove the fastening hardware from the new VTEC rocker arm assembly.

K20A3 engine (2002 model)

Scheme 151

K20A3 engine (2003-2006 models)

Scheme 152

K20A2, K20Z1 engines

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

1. Remove the rocker arm assembly (see «ROCKER ARM ASSEMBLY REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ), then disassemble the rocker arm assembly (see «ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__rocker-arm-and-shaft-disassemblyreassembly) ).
2. Measure the diameter of the shaft at the first rocker location.
3. Zero the gauge (A) to the shaft diameter.
4. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance K20A3 Engine: Standard (New): Intake: 0.025-0.052 mm (0.0010-0.0020 in.) Exhaust: 0.018-0.056 mm(0.0007-0.0022 in.) Service Limit: 0.08 mm (0.003 in.) K20A2, K20Z1 Engines: Standard (New): 0.025-0.052 mm (0.0010-0.0020 in.) Service Limit: 0.08 mm (0.03 in.)
5. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all over tolerance rocker arms. If any VTEC rocker arm needs replacement, replace rocker arms (primary and secondary, or primary, mid, and secondary) as a set.
6. Inspect the rocker arm pistons (A). Push each piston manually. If it does not move smoothly, replace the rocker arm set. NOTE: Apply new engine oil to the pistons when reassembling. K20A3 engine: K20A2, K20Z1 engines
7. Install the rocker arm assembly (see «ROCKER ARM ASSEMBLY INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).

Camshaft Inspection

Note. Do not rotate the camshaft during inspection.

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

1. Remove the rocker arm assembly (see «ROCKER ARM ASSEMBLY REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Put the rocker shaft holders, camshaft and camshaft holders on the cylinder head, then tighten the bolts to the specified torque. NOTE: If the engine does not have bolt (r), 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, 8.7 lbf.ft) 6 mm Bolts: (21), (22), (23)
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.)
5. Unscrew 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 torque as shown in step 2 .
9. Remove the camshaft holders. Measure the widest part 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.)
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.)
11. Measure cam lobe height. Cam Lobe Height Standard (New): CAM LOBE HEIGHT STANDARD INTAKE EXHAUST K20A3 engine (1) 33.925 mm (1.3356 in.) 34.092 mm (1.3422 in.) (2) 29.638 mm (1.1668 in.) K20A2, K20Z1 engines (1) 32.791 mm (1.2910 in.) 32.772 mm (1.2902 in.) (3) 35.534 mm (1.3990 in.) 34.768 mm (1.3688 in.) (2) 32.678 mm (1.2865 in.) 32.661 mm (1.2859 in.) (1) Primary (2) Secondary (3) Mid (4) C/C: Cam Chain K20A3 engine: K20A2, K20Z1 engines

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.

Scheme 165

Scheme 166

Scheme 167

Scheme 168

1. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
2. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve cotters.
3. Install the valve spring compressor attachment and valve spring compressor. Compress the spring and remove the valve cotters.
4. Remove the valve spring compressor, valve spring compressor attachment, spring retainer, and spring.
5. Install the valve guide seal remover.
6. Remove the valve seal.
7. Remove the valve spring seat and valve.

Scheme 169

1. Remove the valves (see «VALVE, SPRING, AND VALVE SEAL REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-spring-and-valve-seal-removal) ).
2. Measure the valve in these areas. K20A3 Engine 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.) K20A2, K20Z1 Engines Intake Valve Dimensions: A Standard (New): 34.85-35.15 mm (1.372-1.384 in.) B Standard (New): 108.8-109.4 mm (4.283-4.307 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): 108.4-109.0 mm (4.268-4.291 in.) C Standard (New): 5.450-5.460 mm (0.2146-0.2150 in.) C Service Limit: 5.42 mm (0.213 in.)

Scheme 170

1. Remove the valves (see «VALVE, SPRING, AND VALVE SEAL REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__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.)
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

1. Valve guide driver, 5.5 mm 07742-0010100
2. Valve guide reamer, 5.5 mm 07HAH-PJ7A100

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

1. Inspect valve stem-to-guide clearance (see «VALVE INSPECTION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
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 special tool and a conventional hammer.
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.
5. Working from the camshaft side, 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.
7. If a valve guide won't move, drill it out with a 8 mm (5/16 inch) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks.
8. Take out 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 special tool 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.)
10. Coat both reamer and valve guide with cutting oil.
11. Rotate the reamer clockwise the full length of the valve guide bore.
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 INSPECTION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ). Verify that a valve slides in the intake and exhaust valve guides without exerting pressure.
15. Inspect the valve seating, if necessary renew the valve seat using a valve seat cutter (see «VALVE SEAT RECONDITIONING»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

1. Inspect valve stem-to-guide clearance (see «VALVE INSPECTION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ). If the valve guides are worn, replace them (see «VALVE GUIDE REPLACEMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-guide-replacement) ) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a valve seat cutter.
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. K20A3 engine: K20A2, K20Z1 engines
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.
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.)
9. If valve stem installed height is over the service limit, replace the valve and recheck. If it is still over 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

1. Stem seal driver 07PAD-0010000
2. Valve spring compressor attachment 07757-PJ1010A

Scheme 181

Scheme 182

Scheme 183

1. Coat the valve stems with 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.
5. Install the valve spring(s) (the 2002 model K20A2 engine has inner and outer valve springs). Place the end of the valve spring with closely wound coils toward the cylinder head.
6. Install the valve retainer.
7. Install the valve spring compressor. Compress the spring, and install the valve cotters.
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.

Scheme 184

Scheme 185

Scheme 186

Scheme 187

1. Reassemble the rocker arm assembly (see «ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__rocker-arm-and-shaft-disassemblyreassembly) ).
2. Clean and dry the No. 5 rocker shaft holder mating surface.
3. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0002,08718-0003, or 08718-0009 evenly to the cylinder head mating surface of the No. 5 rocker shaft holder. NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder head.
5. Remove the bolts from the rocker shaft holder.
6. Punch marks on the VTC actuator and exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder.
7. Set the camshaft holders (B) and cam chain guide B (C) in place.
8. Tighten the bolts 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, 8.7 lbf.ft) 6 mm Bolts: (21), (22), (23)
9. Install the cam chain (see «CAM CHAIN INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-installation) ), and adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-clearance-adjustment) ).

Install the cylinder head in the reverse order of removal

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. Clean the cylinder head and block surface.
2. Install the new cylinder head gasket (A) and dowel pins (B) on the engine block. Always use a new cylinder head gasket.
3. 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.
4. Install the cylinder head on the block.
5. Measure the diameter of each cylinder head bolt at point A and point B.
6. If either diameter is less than 10.6 mm (0.42 in.), replace the cylinder head bolt.
7. Apply new engine oil to the bolt threads and flange of all the cylinder head bolts.
8. 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.
9. 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 5 of the procedure. Do not loosen it back to the specified angle.
10. Install the rocker arm assembly (see «ROCKER ARM ASSEMBLY INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head) ).
11. Install the water bypass hose (A).
12. Tighten the connecting pipe mounting bolt (B) and water bypass line mounting bolts (C), then install the harness holder (D) on the bracket.
13. Install the upper radiator hose (A) and heater hose (B).
14. Install the water bypass hose.
15. Install the intake manifold: K20A3 engine (see «INSTALLATION - K20A3 ENGINE»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ) K20A2, K20Z1 engines (see «INSTALLATION - K20A2, K20Z1 ENGINES»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) )
16. Install the exhaust manifold (see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION»(/acura/rsx/i-2001-2004/remont/exhaust/#intake-manifold-and-exhaust-system) ).
17. Install the cam chain (see «CAM CHAIN INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__cam-chain-installation) ).
18. K20A3 engine: Install the fuel feed line (see «FUEL LINE/QUICK-CONNECT FITTING INSTALLATION»(/acura/rsx/i-2001-2004/remont/fuel-system/#fuel-supply-system__fuel-linequick-connect-fitting-installation) ).
19. Adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/mechanical/#cylinder-head__valve-clearance-adjustment) ).
20. Install the drive belt (see «DRIVE BELT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system__drive-belt-replacement) ).
21. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
22. After installation, check that all tubes, hoses and connectors are installed correctly.
23. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
24. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see step 7 on «COOLANT REPLACEMENT»(/acura/rsx/i-2001-2004/remont/cooling-system-mechanical/#cooling-system) ).
25. 2002-2004 models: Do the engine control module (ECM/powertrain control module (PCM) idle learn procedure (see «ECM/PCM IDLE LEARN PROCEDURE»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#idle-control-system) ).
26. 2005-2006 models: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure see «ECM/PCM RESET (2005-2006 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__ecmpcm-reset-2005-2006-models) ).
27. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(/acura/rsx/i-2001-2004/remont/windows/#power-windows__resetting-the-power-window-control-unit) ).
28. Inspect the idle speed (see «IDLE SPEED INSPECTION»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#idle-control-system__idle-speed-inspection) ).
29. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(/acura/rsx/i-2001-2004/remont/ignition-system/#ignition-system) ).
30. Enter the anti-theft code for the radio, then enter the customer's audio presets.
31. Set the clock.

See also:
• ECM/PCM RESET (2002-2004 MODELS)
• IF THE MIL (MALFUNCTION INDICATOR LAMP) HAS COME ON
• IGNITION COIL REMOVAL/INSTALLATION
• DRIVE BELT REPLACEMENT
• ENGINE INSTALLATION
• VTC OIL CONTROL SOLENOID VALVE REMOVAL/TEST/INSTALLATION
• ECM/PCM RESET (2005-2006 MODELS)
• REMOVAL - K20A3 ENGINE
• FUEL PRESSURE RELIEVING
• COOLANT CHECK
• FUEL LINE/QUICK-CONNECT FITTING REMOVAL
• FUEL LINE/QUICK-CONNECT FITTING INSTALLATION
• ECM/PCM IDLE LEARN PROCEDURE
• RESETTING THE POWER WINDOW CONTROL UNIT
• IDLE SPEED INSPECTION
• CYLINDER HEAD COVER REMOVAL
• VALVE CLEARANCE ADJUSTMENT
• CAM CHAIN REMOVAL
• CAM CHAIN INSTALLATION
• CHAIN CASE OIL SEAL INSTALLATION
• CRANKSHAFT PULLEY REMOVAL AND INSTALLATION
• CAMSHAFT INSPECTION
• ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY
• VALVE, SPRING, AND VALVE SEAL REMOVAL
• VALVE GUIDE REPLACEMENT