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Cylinder Head: Diagnosis Honda S2000 AP1

Mechanical 9 illustrations ~1320 words

Engine Compression Inspection

Note. 2000-2005 models: After this inspection, you must reset the engine control module (ECM) using the Honda Diagnostic System (HDS) (see HOW TO RESET THE ECM ), to clear any diagnostic trouble codes (DTCs). 2006-09 model: After this inspection, you must reset the ECM using the HDS (see HDS CLEAR COMMAND ), otherwise the ECM continues to stop the fuel injectors.

Scheme 54

Scheme 54: Engine Compression Inspection
Scheme 54: Engine Compression Inspection
  1. Warm up the engine to normal operating temperature (cooling fan comes on).
  2. Turn the ignition switch to LOCK (0).
  3. 2000-2005 models: Remove the No. 2 (15 A) fuse from the under-dash fuse/relay box.
  4. 2006-09 models: Connect the HDS to the data link connector (DLC) (see «GENERAL TROUBLESHOOTING INFORMATION»(ref-221328-S01589684132006022400000) ).
  5. 2006-09 models :Turn the ignition switch ON (II).
  6. 2006-09 models : Make sure the HDS communicates with the vehicle and the ECM. If it doesn't, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-351945-S34342936082009122900000) ).
  7. 2006-09 models: Select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
  8. 2006-09 models. Turn the ignition switch to LOCK (0).
  9. Remove the four ignition coils (see «IGNITION COIL REMOVAL/INSTALLATION»(ref-221318-S09707913212006022400000) ).
  10. Remove the four spark plugs.
  11. Attach the compression gauge to the spark plug hole.
  12. Stop on the accelerator pedal to 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, 135 psi)
  13. Measure the compression on the remaining cylinders. Maximum Variation: Within 200 kPa (2.0 kgf/cm, 28 psi)
  14. If the compression is not within specifications, check the following items, then remeasure the compression. Incorrect valve clearance Confirmation of cam timing Damaged or worn cam lobes Damaged or worn valves and seats Damaged cylinder head gasket Damaged or worn piston rings Damaged or worn piston and cylinder bore
  15. Remove the compression gauge from the spark plug hole.
  16. Install the four spark plugs.
  17. Install the four ignition coils
  18. 2000-2005 models: Reinstall the No. 2 (15 A) fuse in the under-dash fuse/relay box.
  19. Select ECM reset using the HDS: 2000-2005 models (see «HOW TO RESET THE ECM»(ref-221328-S42309504302006022400000) ) 2006-08 model (see «HDS CLEAR COMMAND»(ref-221338-S37856226892006022400000) )
  20. Do the ECM idle learn procedure: 2000-2005 models (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ) 2006-08 model (see «ECM IDLE LEARN PROCEDURE»(ref-221342-S09897997502006022400000) )

VTEC Rocker Arm Test

Special Tools Required

  1. Air pressure regulator 07AAJ-PNAA100
  2. Gauge joint adapter 07LAK-PR3A101
  3. VTEC air adapter (2) 07ZAJ-PNAA 100
  4. Air joint adapter 07ZAJ-PNAA300

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Scheme 55

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Scheme 57
  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»(ref-221322-S15452678522006022400000) ).
  3. Set the No. 1 piston at top dead center (TDC) (see step 2 ).
  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 moves independently of the mid rocker arm, go to step 5. 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 mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly.
  5. Repeat step 4 on the remaining rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 6
  6. Check that the air pressure on the shop air compressor gauge indicator is over 400 kPa (4 kgf/cm 2 , 57 psi).
  7. Inspect the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(ref-221322-S34119485472006022400000) ).
  8. Remove the No. 3 and No. 4 camshaft holder bolts, and install the VTEC air adapters (A) finger-tight.
  9. Install the gauge joint adapter (B) to the inspection hole (C).
  10. Connect the air joint adapter (D) to the VTEC air adapters.
  11. Connect the air pressure regulator (E) to the air joint adapter.
  12. Loosen the valve on the regulator, then 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 and secondary rocker arms up and down manually by rotating the crankshaft clockwise.
  13. With the specified air pressure applied and the piston at TDC, move the secondary rocker arm (A). The mid rocker arm (B), primary rocker arm (C), and secondary rocker arm should move together. If the three rocker arms move together, go to step 14. If the three rocker arms does not move together, remove the mid, primary, and secondary rocker arms an assembly, and check that the pistons in the mid and primary rocker arms move smoothly. If rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly.
  14. Repeat step 13 the remaining intake rocker arms with each piston at TDC. When all the rocker arms pass the test, go to step 15.
  15. Remove the special tools.
  16. Tighten the camshaft holder bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
  17. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).

Camshaft Inspection

Note. Do not rotate the camshaft during inspection.

Scheme 58

Scheme 58: Camshaft Inspection
Scheme 58: Camshaft Inspection

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Scheme 59

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Scheme 62
  1. Remove the rocker arm assembly (see «CYLINDER HEAD INSPECTION FOR WARPAGE»(ref-221322-S23128584762006022400000) ).
  2. Disassemble the rocker arm assembly (see «ROCKER ARM AND SHAFT DISASSEMBLY/REASSEMBLY»(ref-221322-S00369422372006022400000) ).
  3. Put the rocker shaft holders, camshafts, and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque. NOTE: Apply new engine oil to the bolt threads. Specified Torque 8x 1.25 mm: 22 N.m (2.2 kgf.m, 16 lbf.ft)
  4. Seat the camshafts by pushing them toward the rear end of the cylinder head.
  5. 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): 0.05-0.15 mm (0.002-0.006 in.) Service Limit: 0.30 mm (0.012 in.)
  6. Remove the camshaft holders and the rocker shaft holders from the cylinder head.
  7. 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.
  8. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.
  9. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 3 .
  10. 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 12 . 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 11. Camshaft-to-Holder Oil Clearance Standard (New): 0.060-0.099 mm (0.002-0.004 in.) Service Limit: 0.15 mm (0.006 in.)
  11. 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 out of tolerance, replace the cylinder head. Camshaft Total Runout Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.04 mm (0.002 in.)
  12. Measure cam lobe height. Cam Lobe Height Standard (New): CAM LOBE HEIGHT STANDARD SPECIFICATION (2000-2003 MODELS) INTAKE EXHAUST PRIMARY 33.677 mm (1.326 in.) 33.716 mm (1.327 in.) MID 36.533 mm (1.438 in.) 35.928 mm (1.414 in. SECONDARY 33.961 mm (1.337 in.) 33.994 mm (1.338 in.) CAM LOBE HEIGHT STANDARD SPECIFICATION (2004-2006-08 MODELS) INTAKE EXHAUST PRIMARY 33.961 mm (1.337 in.) 33.716 mm (1.327 in.) MID 36.421 mm (1.434 in.) 35.660 mm (1.404 in.) SECONDARY 33.961 mm (1.337 in.) 33.716 mm (1.327 in.) PRI: PRIMARY MID: MID SEC: SECONDARY C/C: CAM CHAIN

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