3.0L V6 Engine: Removal & Installation Honda Accord VI

REMOVAL & INSTALLATION

Note. Before disconnecting battery or removing radio fuse, obtain anti-theft code for radio. After battery is reconnected, CODE will appear on radio display. Enter 5-digit code to restore radio operation. If code is entered wrong 3 times, leave radio on at least one hour, then enter code correctly. Anytime radio power is lost, pre-selected radio stations will have to be set. For more information, see owner's manual.

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on major assemblies before removal.

Removal

1. Remove engine hood support struts and secure engine hood in a vertical position. Disconnect battery cables and remove battery. Remove intake air duct. Remove battery base, bracket and engine ground cable. Remove throttle body cover. Loosen throttle cable and cruise control cable lock nuts and slip cable ends out of accelerator linkage.
2. Disconnect engine harness connectors on left side of engine compartment. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8308-S19532374222000082200000) . Disconnect fuel pressure and return hoses at fuel rail. Disconnect brake booster and cruise control vacuum lines at intake manifold. Disconnect harness clamps at firewall.
3. Disconnect battery cables and necessary harness connectors at engine compartment fuse box. Remove starter cable clamps. Disconnect PCM harness connector. PCM is located under dash, next to glove box. Remove PCM harness grommet from firewall. Carefully pull PCM harness through firewall.
4. Remove accessory drive belts. Remove power steering pump retaining bolts and position pump aside with hoses attached. Remove radiator cap. Raise and support vehicle. Remove front wheels. Remove splash shield. Drain coolant. Drain transmission fluid. Drain engine oil.
5. Disconnect heated oxygen sensor harness connector. Remove exhaust pipe between exhaust manifolds and catalytic converter. Remove axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Disconnect shift control cable from transmission. Disconnect power steering hose from retainers. Disconnect front engine mount vacuum hose. Lower vehicle.
6. Disconnect upper and lower radiator hoses at engine. Remove distributor cap. Disconnect heater hoses and engine. Disconnect transmission cooler hoses at transmission. Connect engine hoist to engine to support weight of engine. Remove side engine mount bracket. Remove front and rear engine mount support nut.
7. Remove flange bolts from radius rods. Support subframe. Remove subframe mounting bolts, and lower subframe. Remove A/C compressor retaining bolts, and position A/C compressor aside with hoses attached. Ensure all necessary vacuum hoses, fuel hoses, coolant hoses and harness connectors are disconnected. Lower engine and remove from under vehicle.

Installation

1. To install, reverse removal procedure. Tighten engine/transmission mounts to specification in the following sequence: front mount, rear mount, front cover mount then transmission mount. Improper tightening of engine mounts may cause excessive noise and vibration, and premature mount wear.
2. Use NEW spring clips when installing axle shafts. Install axle shafts until spring clip clicks into differential side gear groove. Ensure all hoses, wire connectors and ground connections are connected properly. Ensure shift and throttle cables are installed and adjusted properly.
3. Verify transaxle shifts smoothly and range indicator agrees with actual transaxle range. Adjust tension on accessory drive belts. Fill fluids to proper levels. After assembling fuel system components, turn ignition on. DO NOT operate starter at this time.
4. Ensure fuel pump operates for approximately 2 seconds and fuel system pressurizes. Repeat 2-3 times and ensure there are no fuel system leaks. Top off all fluids. Start engine. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-8308-S27440276382000082200000) . Recheck all fluids.

1. Disconnect negative cable from battery. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8308-S19532374222000082200000) . Remove radiator cap and drain cooling system. Remove intake air duct. Remove throttle body and intake manifold covers.
2. Loosen lock nuts and slip throttle cable and cruise control cable out of throttle linkage. Remove ignition wire covers. Disconnect necessary hoses and harness connectors. Remove intake manifold retaining bolts and remove intake manifold.

Clean gasket surfaces. Install intake manifold, using NEW gaskets. Tighten bolts in sequence to specification in 2-3 stages. See TORQUE SPECIFICATIONS. (Scheme 4) To complete installation, reverse removal procedure.

Scheme 4

Remove exhaust manifold cover. Remove front exhaust pipe. Remove manifold nuts and manifold. Remove gasket. Clean gasket surfaces. Install exhaust manifold, using NEW gasket and self-locking nuts. Using a crisscross pattern, tighten nuts to specification in 3 stages, starting with inner nuts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-8308-S14728854402000082200000). Disconnect fuel pressure and return lines. Remove cylinder head covers. Disconnect fuel pressure and return hoses at fuel rail. See «FUEL PRESSURE RELEASE»(ref-8308-S19532374222000082200000). Disconnect brake booster and cruise control vacuum lines at intake manifold.
2. Remove accessory drive belts. Remove ground cable bolt at top of generator. Support engine. Remove engine mount bracket by timing belt cover. Remove power steering pump retaining bolts and position pump aside with hoses attached. Remove generator.
3. Disconnect necessary harness connectors. Remove fuel rails. Remove timing belt. See «TIMING BELT»(ref-8308-S36871384042000082200000). Disconnect upper and lower radiator hoses at engine. Disconnect heater hoses at engine. Remove water passage assembly (thermostat housing).
4. Remove camshaft pulleys and timing belt back covers. To prevent warpage of heads, remove cylinder head bolts 1/3 turn at a time in reverse order of tightening sequence until all bolts are loosened. (Scheme 5) Remove cylinder heads.

Scheme 5

1. Ensure all mating surfaces are clean. Turn crankshaft so that No. 1 piston is at TDC. Turn camshafts so that both are aligned at TDC. see scheme 2
2. Clean oil control orifice (located in upper right corner of head mounting surface) and install NEW "O" rings. Ensure dowel pins are installed. Install NEW cylinder head gasket.
3. Apply a light coat of engine oil to cylinder head bolts and washers. Tighten cylinder head bolts in sequence in 3 steps. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000). (Scheme 4) Install exhaust manifolds and tighten nut in 2 step in a crisscross pattern. Always use new exhaust manifold gaskets.
4. Install exhaust pipe. Install timing belt. See «TIMING BELT»(ref-8308-S36871384042000082200000). Adjust valves. See «VALVE CLEARANCE ADJUSTMENT»(ref-8308-S28795296072000082200000) under ADJUSTMENTS. Install cylinder head covers and tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000).
5. To complete installation, reverse removal procedures. Tighten all bolt to specification. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000). Ensure all tubes, hoses and connectors are installed correctly.
6. Turn ignition on. Ensure fuel pump operates for 2 seconds and that there are no fuel system leaks. Top off all fluids. Start engine. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-8308-S27440276382000082200000). Recheck all fluids.

Remove timing belt. See TIMING BELT . Remove crankshaft timing belt drive pulley. DO NOT scratch or score crankshaft and/or oil seal mounting surface. Remove front crankshaft oil seal.

Apply light coating of grease to crankshaft and lip of new seal if seal is not already prelubed. Tap seal into place using seal driver. Ensure seal is fully seated and is straight. To complete installation, reverse removal procedure.

1. Raise and support vehicle. Remove front wheels and splash shield. Remove accessory drive belts. Support engine with a cushioned jack. Remove 3 bolts attaching side engine mount and remove mount. Remove dipstick and pipe. Remove crankshaft pulley. Remove upper and lower timing belt covers.
2. If reusing timing belt, mark direction of rotation on belt before removing. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. see scheme 2
3. Remove one battery clamp and bevel threaded end. To hold timing belt tensioner in place, screw battery clamp in as shown (hand tight) in illustration. (Scheme 6)
4. Remove engine mount bracket. Loosen timing belt idler pulley bolt 5 or 6 turns and remove timing belt. Inspect camshaft and crankshaft seals, replace if leaking. Inspect water pump and idler pulley, replace as necessary.

Scheme 6

1. To install, clean timing belt covers. Ensure crankshaft pulley TDC mark aligns with pointer on oil pump. Ensure TDC marks on camshaft pulleys align with pointers on back covers. see scheme 2 NOTE: Handle tensioner carefully so that oil inside tensioner does not spill or leak. Replenish oil if spilled. Total capacity is.22 oz. (6.5 ml)
2. Remove battery clamp. Remove tensioner. Place tensioner in soft-jaw vise by boss with maintenance bolt pointing up. DO NOT clamp housing of tensioner. (Scheme 7) Remove maintenance bolt.
3. Insert flat-blade screwdriver into maintenance hole. DO NOT damage maintenance bolt threads or sealing surface. Place Holder (14540-P8A-A01) on tensioner while turning screwdriver clockwise. Once compressed and holder in place, install maintenance bolt and tighten to 71 INCH lbs. (8 N.m).
4. Install tensioner and tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000). Install timing belt in a counterclockwise sequence starting at crankshaft drive pulley. Tighten idler pulley bolt to specification. Remove holder from tensioner.
5. Rotate crankshaft clockwise 5 or 6 revolutions. Recheck timing marks for proper alignment. see scheme 2 If timing marks are still aligned, go to next step. If timing marks are not aligned, repeat removal and installation procedures. To complete installation, reverse removal procedures. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000).

Scheme 7

Information is not available from manufacturer.

Information is not available from manufacturer.

Scheme 8

Disconnect negative battery cable. Remove transaxle assembly. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Mark drive plate for installation reference. Remove drive plate. Remove seal from rear cover.

Apply light coating of grease to crankshaft and lip of new seal. Using Seal Driver (07749-0010000) and Driver Attachment (07948-SB00101), install seal. Install drive plate. Tighten drive plate bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Drain cooling system. Remove timing belt. See TIMING BELT . Remove timing belt tensioner. Remove water pump bolts, water pump, and "O" ring.

Clean "O" ring mating surfaces. Install NEW water pump "O" ring. Install water pump. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

Valve Spring Removal

Using an appropriate-size socket and a plastic mallet, lightly tap valve retainers to loosen valve keepers. Using valve spring compressor and Valve Spring Compressor Attachment (07757-PJ1010A), compress valve spring. Remove valve keepers, valve retainer and spring. Using a valve guide seal remover, remove valve seal, spring seat and valve.

Valve Spring Installation

To install, reverse removal procedure. After installation lightly tap end of each valve stem 2 or 3 times with a plastic mallet to ensure proper seating of valve and keepers.

Valve Guide Removal

1. Select proper replacement guides and chill them in a freezer for an hour. Use a hot plate or oven to evenly heat cylinder head to 300°F (150°C). Use a 1/4 in. (6.4 mm) valve guide driver, or fabricate valve guide remover from an air impact chisel. Using an air hammer and valve guide remover, drive valve guide 5/64" (2 mm) toward combustion chamber. This will knock off carbon and make removal easier.
2. Turn head over. Working from combustion chamber side of head, drive valve guide out toward camshaft side of head. If valve guide does not move, drill valve guide using a 5/16" (8 mm) drill bit, then try to drive it out again. CAUTION: Drill guides in extreme cases only. Cylinder head damage can occur if valve guide breaks.

Valve Guide Installation

1. Remove new valve guides from freezer, one at a time, as needed. Apply a thin coat of clean engine oil to outside of valve guide. Install valve guides from camshaft side of cylinder head using valve guide driver.
2. Drive each guide into heated cylinder head to specified valve guide installed height. See «CYLINDER HEAD»(ref-8308-S25805931512000082200000) table under ENGINE SPECIFICATIONS. If replacing all valve guides, reheat cylinder head as necessary.

Crankshaft Installation

1. Before installing main bearings and rod bearings, apply a coat of engine oil to crankshaft side of bearing. Install main bearing halves in cylinder block. Install thrust washers in No. 3 journal of cylinder block. Lower crankshaft into block.
2. Install bearings, bearing caps, and tighten bolts to specification in sequence. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000). see scheme 15 Check crankshaft end play and adjust as necessary. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-8308-S32496631952000082200000) table under ENGINE SPECIFICATIONS.

Note. Ensure arrow on top of piston faces timing belt side of engine. Ensure connecting rod oil hole and offset mark on top of piston face rear of engine (passenger side).

Piston Installation

1. Before installing piston, apply a coat of engine oil to ring grooves and cylinder bores. Remove connecting rod caps and slip a 12-inch rubber hose over threaded ends of connecting rod bolts. Rotate crankshaft to Bottom Dead Center (BDC). Align piston rings. see scheme 11
2. Using a ring compressor and wooden hammer handle, install piston/connecting rod assemblies. Ensure marks are aligned on connecting rod caps and install rod caps and bearings. Tighten connecting rod nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000). Recheck rod bearing clearance using plastigage and retighten cap nuts to specification. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000).

Removal & Disassembly

Drain engine oil and remove splash shield. Turn crankshaft until No. 1 piston is at TDC. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Remove Crankshaft Position (CKP) sensor and timing belt tensioner. Remove stopper plate and timing belt drive pulley. Remove oil filter and oil filter base. Remove oil pan, oil screen, baffle plate and oil pump. Separate oil pump housing and cover.

Reassembly & Installation

1. Remove old oil seal from oil pump, avoiding scratching pump surface. Using Seal Driver (07GAD-PH70201), gently tap NEW oil seal until driver bottoms against pump. Reassemble oil pump, applying liquid thread lock to pump housing screws. Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000) . Ensure oil pump turns freely. Install dowel pins and NEW "O" ring on oil pump.
2. Apply thin bead of liquid gasket to center of mating surfaces on oil pump and cylinder block and to surface inside of bolt holes. Install components within 5 minutes of applying liquid gasket. If components are not installed within time limit, clean residue and reapply. Wait at least 20 minutes before filling engine with oil. To complete installation, reverse removal procedure. See «TORQUE SPECIFICATIONS»(ref-8308-S17658673862000082200000) .