Cylinder Head: Removal & Installation Honda S2000 AP1

Crankshaft Pulley Removal and Installation

Special Tools Required

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

Scheme 63

1. Hold the pulley with holder handle (A) and holder attachment (B).
2. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar.

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1. Remove ant oil and clean the bolt (A), washer (B), pulley (C), and crankshaft (D). Lubricate with new engine oil as shown.
2. Install the crankshaft pulley, and tighten the bolt to 260 N.m (26.5 kgf.m, 192 lbf.ft). Do not use an impact wrench. Hold the pulley with the holder handle (A) and holder attachment (B). Tighten the bolt with a torque wrench and heavy duty 19 mm socket (C).

Cam Chain Removal

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

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1. Relieve fuel pressure: 2000-2005 models (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) ) 2006-09 model (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) )
2. Do the battery terminal disconnection procedure ( see «DISCONNECTION»(ref-221385-S40144297672009111300000) ).
3. Drain the engine coolant (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
4. Drain the engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
5. Loosen the water pump pulley bolts.
6. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
7. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-221322-S20184296852006022400000) ).
8. 2000-2005 models: Remove the vacuum tank.
9. Disconnect the water bypass hose (A), then remove the three bolts (B) securing the water bypass tube (C).
10. Remove the water pump pulley.
11. Remove the auto-tensioner (see «DRIVE BELT AUTO-TENSIONER REPLACEMENT»(ref-351946-S33113324462009122900000) ).
12. Remove the alternator (see «ALTERNATOR REMOVAL AND INSTALLATION»(ref-351946-S17008440722009122900000) ).
13. Remove the idler pulley (A), then remove the idler pulley base (B).
14. Remove the oil pan (see «OIL PAN REMOVAL»(ref-221323-S25540807762006022400000) ).
15. Remove the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(ref-221322-S12109820282006022400000) ).
16. Remove the chain case.
17. Remove the CKP pulse plate (see «CKP PULSE PLATE REPLACEMENT»(ref-221322-S16953494212006022400000) ).
18. Remove the oil pump chain guide.
19. Remove the cam chain.

Cam Chain Installation

Note. Keep the cam chain away from magnetic field.

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1. Set the crankshaft sprocket so that the No. 1 piston is at top dead center (TDC). Align the key (A) on the sprocket and crankshaft with the pointer (B) on the engine block.
2. Install the cam chain with the colored piece (A) aligned with the punch mark (B) on the crankshaft sprocket.
3. Install the oil pump chain guide.
4. Install the CKP pulse plate (see «CKP PULSE PLATE REPLACEMENT»(ref-221322-S16953494212006022400000) ).
5. 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»(ref-221322-S08292188372006022400000) ).
6. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
7. Clean and dry the chain case mating surfaces.
8. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
9. Apply a light coat of new engine oil to the lip of the chain case oil seal, then install the dowel pins (A) and the chain case (B) using a new O-ring (C).
10. Install the crankshaft position (CKP) sensor.
11. Install the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(ref-221322-S12109820282006022400000) ).
12. Install the oil pan (see «OIL PAN INSTALLATION»(ref-221323-S13350950282006022400000) ).
13. Install the idler pulley base (A), then install the idler pulley (B).
14. Install the alternator (see «ALTERNATOR REMOVAL AND INSTALLATION»(ref-351946-S17008440722009122900000) ).
15. Install the auto-tensioner (see «DRIVE BELT AUTO-TENSIONER REPLACEMENT»(ref-351946-S33113324462009122900000) ).
16. Install the water pump pulley.
17. Connect the water bypass hose (A), and tighten the three bolts (B) securing the water bypass tube.
18. Install the cylinder head (see «CAMSHAFT GEAR INSTALLATION»(ref-221322-S05850180812006022400000) ) with using the following process by installing the cam chain sprocket assembly. Make sure the crankshaft pulley is at TDC. Place the idler gear/cam chain sprocket assembly and idler gear collar into the cylinder head. Install the cam chain on the sprocket with the one punch mark (A) aligned with the center of the two colored pieces (B). Fit the cam chain sprocket assembly into the cylinder head. Turn the cam chain sprocket assembly counterclockwise to relieve cam chain free play, and check the alignment of the TDC mark (C) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
19. Install the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
20. Install the vacuum tank.
21. After installation, check that all tubes, hoses, and connectors are installed correctly.
22. After assembly, wait at least 30 minutes before filling the engine with oil.
23. Do the battery terminal reconnection procedure. ( see «RECONNECTION»(ref-221385-S40426783402009111300000) ).
24. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
25. Refill the engine with engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
26. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
27. 2000-2005 models: Do the engine control module (ECM) idle learn procedure (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ).
28. 2006-09 model: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see «HDS CLEAR COMMAND»(ref-221338-S37856226892006022400000) ).
29. Inspect the idle speed: 2000-2005 models (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ). 2006-09 model (see «IDLE SPEED INSPECTION»(ref-221342-S10994389392006022400000) ).
30. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(ref-221318-S03270425022006022400000) ).

Chain Case Oil Seal Installation

Special Tools Required

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

Scheme 81

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1. Apply a light coat of new engine oil around the chain case oil seal.
2. Use the driver and the attachment to drive a new oil seal squarely into the chain case to the specified installed height.
3. Measure the distance between the chain case surface (A) and the oil seal (B). Oil Seal Installed Height: 34.0-34.7 mm (1.34-1.37 in.)

CKP Pulse Plate Replacement

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. Keep the cam chain away magnetic field.

Scheme 83

1. Relieve fuel pressure: 2000-2005 models (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) ) 2006-09 model (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) )
2. Do the battery terminal disconnection procedure ( see «DISCONNECTION»(ref-221385-S40144297672009111300000) ).
3. Drain the engine coolant (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
4. Drain the engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
5. Loosen the water pump pulley bolts.
6. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
7. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-221322-S20184296852006022400000) ).
8. 2000-2005 models: Remove the vacuum tank (see step 8 ).
9. Disconnect the water bypass hose, then remove the three bolts securing the water bypass tube (see step 9 ).
10. Remove the water pump pulley (see step 10 ).
11. Remove the auto-tensioner (see «DRIVE BELT AUTO-TENSIONER REPLACEMENT»(ref-351946-S33113324462009122900000) ).
12. Remove the alternator (see «ALTERNATOR REMOVAL AND INSTALLATION»(ref-351946-S17008440722009122900000) ).
13. Remove the idler pulley, then remove the idler pulley base (see step 13 ).
14. Remove the oil pan (see «OIL PAN REMOVAL»(ref-221323-S25540807762006022400000) ).
15. Remove the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(ref-221322-S12109820282006022400000) ).
16. Remove the crankshaft position (CKP).
17. Remove the chain case.
18. Remove the CKP pulse plate.
19. Install the CKP pulse plate.
20. 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»(ref-221322-S08292188372006022400000) ).
21. Remove any old liquid gasket from the chain case mating surfaces, bolt, and bolt holes.
22. Clean and dry the chain case mating surfaces.
23. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder block mating surface of the chain case (see «CAM CHAIN INSTALLATION»(ref-221322-S34674341402006022400000) ). NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
24. Apply a light coat of new engine oil around the chain case oil seal, then install the dowel pins and the chain case using a new O-ring.
25. Install the CKP sensor.
26. Install the crankshaft pulley (see «CRANKSHAFT PULLEY REMOVAL AND INSTALLATION»(ref-221322-S12109820282006022400000) ).
27. Install the oil pan (see «OIL PAN INSTALLATION»(ref-221323-S13350950282006022400000) ).
28. Install the idler pulley base, then install the idler pulley (see step 13 ).
29. Install the alternator (see «ALTERNATOR REMOVAL AND INSTALLATION»(ref-351946-S17008440722009122900000) ).
30. Install the auto-tensioner (see «DRIVE BELT AUTO-TENSIONER REPLACEMENT»(ref-351946-S33113324462009122900000) ).
31. Install the water pump pulley (see step 16 ).
32. Install the water bypass hose, and tighten the three bolts securing the water bypass tube (see step 17 ).
33. Install the cylinder head (see «CAMSHAFT GEAR INSTALLATION»(ref-221322-S05850180812006022400000) ).
34. Install the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
35. Install the vacuum tank (see step 20 ).
36. After installation, check that all tubes, hose, and connectors are installed correctly.
37. After assembly, wait at least 30 minutes before filling the engine with oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
38. Do the battery terminal reconnection procedure (see «RECONNECTION»(ref-221385-S40426783402009111300000) ).
39. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
40. Refill the engine with engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
41. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
42. 2000-2005 models: Do the engine control module (ECM) idle learn procedure (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ).
43. 2006-09 model: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see «HDS CLEAR COMMAND»(ref-221338-S37856226892006022400000) ).
44. Inspect the idle speed: 2000-2005 models (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ) 2006-09 model (see «IDLE SPEED INSPECTION»(ref-221342-S10994389392006022400000) )
45. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(ref-221318-S03270425022006022400000) ).

Scheme 84

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1. 2000-2005 models: Disconnect the camshaft position (CMP) sensor A (top dead center (TDC) sensor 1) connector and CMP sensor B (TDC sensor 2) connector.
2. 2006-08 model: Disconnect the camshaft position (CMP) sensor connector.
3. Remove the dipstick (A), positive crankcase ventilation (PCV) hose (B), and breather hose (C).
4. Remove the harness clamps (A).
5. Remove the ignition coil (see «IGNITION COIL REMOVAL/INSTALLATION»(ref-221318-S09707913212006022400000) ).
6. Remove the cylinder head cover.

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1. Thoroughly clean the head cover gasket and the groove.
2. Install the head cover gasket in the groove of the cylinder head cover.
3. Set the spark plug seal (A) on the spark plug tube. Install the cylinder head cover (B) on the cylinder head. NOTE: Take care not to damage the spark plug seals when installing the cylinder head cover. Visually inspect the spark plug seals for damage.
4. Inspect the cylinder head cover washers. Replace any washers and rubber seals that are damaged or deteriorated.
5. Clean the washer mating surfaces of the cylinder head cover.
6. Install the head cover washers (A).
7. Make sure the rubber seals (B) are securely seated on the cylinder head cover.
8. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 N.m (1.2 kgf.m,8.7 lbf.ft).
9. Install the ignition coil (see «IGNITION COIL REMOVAL/INSTALLATION»(ref-221318-S09707913212006022400000) ).
10. Install the harness clams (A).
11. Install the positive crankcase ventilation (PCV) hose (A) and breather hose (B), then insert the dipstick (C).
12. 2000-2005 models: Connect the camshaft position (CMP) sensor A (top dead center (TDC) sensor 1) connector and CMP sensor B (TDC sensor 2) connector.
13. 2006-09 model: Connect the camshaft position (CMP) sensor connector.

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.

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1. Relieve fuel pressure: 2000-2005 models (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) ) 2006-08 model (see «FUEL PRESSURE RELIEVING»(ref-221332-S01007787392006022400000) )
2. Do the battery terminal disconnection procedure (see «DISCONNECTION»(ref-221385-S40144297672009111300000) ).
3. Drain the engine coolant (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
4. Drain the engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
5. 2000-2005 models: Disconnect the air hose (A) and breather pipe (B), then remove the air cleaner housing cover (C) and air cleaner assembly (D).
6. 2006-09 model: Disconnect the intake air temperature (IAT) sensor connector (A) and breather pipe (B), remove the manifold absolute pressure (MAP) sensor harness (C) from the holder, then remove the air cleaner housing cover (D) and air cleaner assembly (E).
7. 2000-2005 models: Disconnect the air control solenoid valve connector (A) and vacuum hoses (B), remove the harness clamps (C), then remove the intake air cleaner housing (D).
8. 2006-09 model: Remove the IAT sensor harness clamps (A), the remove the intake air cleaner housing (B).
9. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
10. 2000-2005 models: Remove the throttle cable.
11. 2000-2005 models: Remove the fuel feed hose (A), fuel return hose (B), and brake booster vacuum hose (C).
12. 2006-09 model: Remove the intake manifold cover.
13. 2006-09 model: Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose (B) and brake booster vacuum hose (C).
14. Disconnect the evaporative emission (EVAP) canister hose.
15. 2000-2005 models: Remove the bolt (A) securing the intake manifold bracket, and remove the air hose (B).
16. 2006-08 model: Remove the bolt (A) securing the intake manifold bracket.
17. Remove the water outlet cover.
18. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and intake manifold. Four fuel injector connectors Intake air temperature (IAT) sensor connector (2000-2005 models) Idle air control (IAC) valve connector (2000-2005 models) Throttle position (TP) sensor connector (2000-2005 models) Throttle body connector (2006-08 model) Manifold absolute pressure (MAP) sensor connector Primary heated oxygen sensor (primary HO2S) connector (2000-2005 models) A/F sensor connector (2006-08 model) Engine coolant temperature (ECT) sensor connector (2000-2005 models) Engine coolant temperature (ECT) sensor 1 connector (2006-08 model) Rocker arm oil control solenoid (VTEC solenoid valve) connector Rocker arm oil pressure switch (VTEC oil pressure switch) connector Crankshaft position (CKP) sensor connector
19. 2000-2005 models: Remove two bolts (A) securing the intake manifold bracket, and remove the water bypass hose (B).
20. 2006-09 model: Remove the water bypass hose (A), remove the EVAP hose (B) and its bracket (C), remove wire harness clamp (D), then remove the intake manifold bracket (E).
21. Remove the four bolts securing the exhaust manifold cover.
22. Remove the three bolts (A), and loosen the bolt (B), then remove the heat shield (C).
23. Remove the exhaust manifold cover, then remove the exhaust manifold bracket (A) and the exhaust manifold (B).
24. 2000-2005 models: Remove the injectors (see «INJECTOR REPLACEMENT»(ref-221329-S03017427892006022400000) ).
25. Remove the intake manifold stay (A) and the intake manifold (B).
26. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
27. Set the No. 1 piston at top dead center (TDC). The TDC marks (A) on the cam chain sprocket should align with the cylinder head surface.
28. Remove the end cover (A) and nozzle (B) from the cam chain auto-tensioner.
29. Thread a nut (A) onto a 5 x 0.8 mm bolt that is at least 40 mm long (B), then thread the bolt into the maintenance hole in the cam chain auto-tensioner.
30. Turn the bolt clockwise to compress the cam chain auto-tensioner, and lock the bolt with the nut.
31. Remove the cam chain auto-tensioner.
32. Loosen the rocker arm adjusting screws (A).
33. Remove the camshaft holders and camshafts. To prevent damaging the camshafts, unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern.
34. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).
35. Remove the idler gear/cam chain sprocket assembly, idler gear collar, and washer.
36. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all the bolts are loose.
37. Remove the cylinder head.

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Scheme 122

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
2. Hold the camshaft with an open-end wrench, then loosen the bolt. NOTE: This bolt has left hand threads.
3. Remove the camshaft position (CMP) pulse plate A.
4. Clean the bolt, then apply new engine oil to the threads.
5. Align the CMP pulse plate A groove with the pin on the camshaft end, then install the CMP pulse plate A.
6. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).

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Scheme 124

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
2. Hold the exhaust camshaft with an open-end wrench, then loosen the bolt. NOTE: This bolt has left hand threads.
3. Remove the camshaft position (CMP) pulse plate B.
4. Clean the bolt, then apply new engine oil to the threads.
5. Align the CMP pulse plate B groove with the pin on the camshaft end, then install the CMP pulse plate B.
6. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).

Scheme 125

Scheme 126

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
2. Hold the camshaft with an open-end wrench, then loosen the bolt. NOTE: This bolt has left hand threads.
3. Remove the camshaft position (CMP) pulse plate.
4. Clean the bolt, then apply new engine oil to the threads.
5. Locate the position mark to the outside and align the CMP pulse plate groove with the pin on the camshaft end, then install the CMP pulse plate.
6. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).

Scheme 127

Scheme 128

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
2. Loosen the rocker arm adjusting screws (see step 2 ).
3. Remove the camshaft holders and camshafts. To prevent damaging the camshafts, unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern.
4. Hold the camshaft with an open-end wrench, then loosen the camshaft gear mounting nut.
5. Remove the camshaft gear. NOTE: The exhaust camshaft gear has a groove (A) in the face. The intake camshaft does not have a groove.

Scheme 129

1. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-221322-S20184296852006022400000) ).
2. Inspect the camshaft (see «CAMSHAFT INSPECTION»(ref-221322-S07351082982006022400000) ).
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 105 mm (4.13 in.). Cylinder Head Height Standard (New): 104.95-105.05 mm (4.132-4.136 in.)

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Scheme 131

1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-221322-S15452678522006022400000) ).
2. Loosen the rocker arm adjusting screws (A).
3. Remove the camshaft holders and camshafts. To prevent damaging the camshafts, unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern.
4. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

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.

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Scheme 135

1. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-221322-S20184296852006022400000) ).
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. Compress the spring and remove the valve cotters.
4. Remove the valve spring compressor, then remove the valve retainer and valve spring.
5. Install the valve guide seal remover.
6. Remove the valve seal.
7. Remove the valve spring seat and valve.

Scheme 136

1. Remove the valves (see «VALVE, SPRING, AND VALVE SEAL REMOVAL»(ref-221322-S33196833832006022400000) ).
2. Measure the valve in these areas. Intake Valve Dimensions A Standard (New): 35.90-36.10 mm (1.413-1.421 in.) B Standard (New): 108.85-109.15 mm (4.285-4.297 in.) C Standard (New): 5.48-5.49 mm (0.2157-0.2161 in.) C Service Limit: 5.45 mm (0.215 in.) D Standard (New): 0.55-0.85 mm (0.022-0.033 in.) D Service Limit: 0.40 mm (0.016 in.) Exhaust Valve Dimensions A Standard (New): 30.90-31.10 mm (1.217-1.224 in.) B Standard (New): 107.60-107.90 mm (4.236-4.248 in.) C Standard (New): 5.45-5.46 mm (0.2146-0.2150 in.) C Service Limit: 5.42 mm (0.213 in.) D Standard (New): 0.85-1.15 mm (0.033-0.045 in.) D Service Limit: 0.70 mm (0.028 in.)

Scheme 137

1. Remove the valves (see «VALVE, SPRING, AND VALVE SEAL REMOVAL»(ref-221322-S33196833832006022400000) ).
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): 0.04-0.10 mm (0.002-0.004 in.) Service Limit: 0.16 mm (0.006 in.) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.10-0.16 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): 0.02-0.05 mm (0.001-0.002 in.) Service Limit: 0.08 mm (0.003 in.) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.05-0.08 mm (0.002-0.003 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-PJ7010B

Scheme 138

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1. Inspect valve stem-to-guide clearance (see «VALVE INSPECTION»(ref-221322-S12700169632006022400000) ).
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 in.) 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 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: 16.0-17.0 mm (0.630-0.669 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 drawing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve (see «VALVE STEM-TO-GUIDE CLEARANCE INSPECTION»(ref-221322-S40951477072006022400000) ). Verify that a valve slides in the intake and exhaust valve guides without getting stuck.
15. Inspect the valve seating, if necessary renew the valve seat using a valve seat cutter (see «VALVE SEAT RECONDITIONING»(ref-221322-S27757205722006022400000) ).

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Scheme 146

1. Inspect valve stem-to-guide clearance (see «VALVE STEM-TO-GUIDE CLEARANCE INSPECTION»(ref-221322-S40951477072006022400000) ). If the valve guides are worn, replace them (see «VALVE STEM-TO-GUIDE CLEARANCE INSPECTION»(ref-221322-S40951477072006022400000) ) 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 edge of the seat with the 32 ° cutter and the lower edge of the seat with the 60 ° cutter. Check the width of the seat and adjust accordingly.
5. Make one more very light pass with the 45 ° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width Intake: Standard (New): 1.05-1.35 mm (0.041-0.053 in.) Service Limit: 1.80 mm (0.071 in.) Exhaust: 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 60 ° 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 32 ° cutter 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): 44.1-44.4 mm (1.736-1.748 in.) Service Limit: 44.7 mm (1.760 in.) Exhaust Valve Stem Installed Height Standard (New): 44.2-44.5 mm (1.740-1.752 in.) Service Limit: 44.8 mm (1.764 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-PJ 1010A

Scheme 147

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Scheme 149

1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the valve guide seal installer (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 and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head.
6. Install the valve spring compressor. Compress the spring and install the valve cotters.
7. Remove the valve spring compressor.
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 150

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Scheme 153

1. Make sure the crankshaft pulley is at top dead center (TDC). Align the TDC mark (A) on the crankshaft pulley with the pointer (B) on the chain case.
2. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B).
3. Check the alignment of the TDC marks (A) on the cam chain sprocket with the cylinder head surface.
4. Align the TDC marks (B) on the intake camshaft gear (C) and the exhaust camshaft gear (D), and install the camshafts.
5. Apply new engine oil to the bolt threads of all the camshaft holder bolts.
6. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft). To prevent damaging the camshafts, tighten the bolts two turns at a time, in the sequence shown.
7. Adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(ref-221322-S34119485472006022400000) ).
8. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).

Scheme 154

Scheme 155

1. Install the camshaft gear (A). NOTE: The exhaust camshaft gear has a groove (B) in the face. The intake camshaft gear does not have a groove. Be sure to install the correct camshaft gear on each camshafts.
2. Apply new engine oil to the threads of the camshaft gear mounting nut (C), then install it.
3. Hold the camshaft with an open-end wrench, then tighten the camshaft gear mounting nut. Specified Torque: 118 N.m (12.0 kgf.m, 86.8 lbf.ft)

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1. Measure the diameter of each cylinder head bolt at point A and point B. If either diameter is less than 11.5 mm (0.45 in.), replace the cylinder head bolt.
2. Clean and dry the cylinder head, engine block, and chain case mating surfaces.
3. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, to the shaded areas (A) of the cylinder head gasket mating surface of the engine block and chain case. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
4. Install the dowel pins (A) and the new cylinder head gasket (B).
5. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the cylinder head mating surface of the block and chain case within 5 mm of the edge of the cylinder head gasket. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
6. Install the cylinder head on the engine block.
7. Apply new engine oil to the threads and flange of all the cylinder head bolts.
8. Tighten the cylinder head bolts in sequence to 29 N.m (3.0 kgf.m, 22 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.
9. 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 °.
10. Tighten the 8 mm bolts (A) to 22 N.m (2.2 kgf.m, 16 lbf.ft).
11. Make sure the crankshaft pulley is at top dead center (TDC). Align the TDC mark (A) on the crankshaft pulley with the pointer (B) on the chain case.
12. Assemble the idler gear (A) and cam chain sprocket (B) with three mounting bolts (C). Torque the bolts to 13 N.m (1.3 kgf.m, 9.4 lbf.ft).
13. Place the idler gear/cam chain sprocket assembly and idler gear collar into the cylinder head.
14. Install the cam chain on the sprocket, then fit the assembly into the cylinder head.
15. Turn the idler gear counterclockwise to relieve cam chain free play, and check the alignment of the TDC marks (A) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the idler gear from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
16. Apply new engine oil to the idler gear/cam chain sprocket center bolt threads (A). Install a new O-ring (B) on the bolt.
17. Install the washer (C) on the idler gear, and tighten the center bolt.
18. Clamp the cam chain auto-tensioner in a soft-jawed vise.
19. Turn the 5 x 0.8 mm bolt (A) clockwise to compress the bottom of the auto-tensioner, then insert the set pin (B), P/N 14511-PCX-005.
20. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new O-ring (A), then install the nozzle (B) and end cover (C).
21. Install the cam chain auto-tensioner (A) in the cylinder head with new O-rings (B).
22. Remove the maintenance bolt (C) from the cylinder head.
23. Remove the set pin (A) from the cam chain auto-tensioner. Reinstall the maintenance bolt (B) with a new washer (C).
24. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B).
25. Check the alignment of the TDC marks (A) on the cam chain sprocket with the cylinder head surface.
26. Align the TDC marks (B) on the intake camshaft gear (C) and the exhaust camshaft gear (D), and install the camshafts.
27. Apply new engine oil to the bolt threads of all the camshaft holder bolts.
28. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft). To prevent damaging the camshafts, tighten the bolts two turns at a time, in the sequence shown.
29. Make sure the camshaft gears are at TDC.
30. Adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(ref-221322-S34119485472006022400000) ).
31. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-221322-S09112251732006022400000) ).
32. Install the intake manifold (A) with a new gasket (B), then install the intake manifold stay.
33. 2000-2005 models: Install the injectors (see «INJECTOR REPLACEMENT»(ref-221329-S03017427892006022400000) ).
34. Install the exhaust manifold (A) using new gaskets (B) and new self-locking nuts (C).
35. Install the exhaust manifold bracket (D). Make sure the smooth sides of the washers (E) face the exhaust manifold bracket.
36. Put the exhaust manifold cover on the exhaust manifold.
37. Install the heat shield.
38. Tighten the four bolts securing the exhaust manifold cover.
39. 2000-2005 models: Install the water bypass hose (A), and tighten the two bolts (B) securing the intake manifold bracket.
40. 2006-08 model: Install the intake manifold bracket (A), then install the evaporative emission (EVAP) hose (B) and its bracket (C), install wire harness clamp (D) and the water bypass hose (E).
41. Install the engine wire harness connectors and wire harness clamps to the cylinder head and intake manifold. Four fuel injector connectors Intake air temperature (IAT) sensor connector (2000-2005 models) Idle air control (IAC) valve connector (2000-2005 models) Throttle position (TP) sensor connector (2000-2005 models) Throttle body connector (2006-08 model) Manifold absolute pressure (MAP) sensor connector Primary heated oxygen sensor (primary HO2S) connector (2000-2005 models) A/F sensor connector (2006-08 model) Engine coolant temperature (ECT) sensor connector (2000-2005 models) Engine coolant temperature (ECT) sensor 1 connector (2006-08 model) Rocker arm oil control solenoid (VTEC solenoid valve) connector Rocker arm oil pressure switch (VTEC oil pressure switch) connector Crankshaft position (CKP) sensor connector
42. Install the water outlet cover (A) with a new O-ring (B).
43. 2000-2005 models: Install the air hose (A), and tighten the bolt (B) securing the intake manifold bracket.
44. 2006-08 model: Install the bolt (A) securing the intake manifold bracket.
45. Connect the evaporative emission (EVAP) canister hose.
46. 2000-2005 models: Install the brake booster vacuum hose (A), fuel return hose (B), and fuel feed hose (C), using new washers (D).
47. 2006-08 model: Install the brake booster vacuum hose (A) and fuel feed hose (B), then quick-connect fitting cover (C).
48. 2006-08 model: Install the intake manifold cover.
49. 2000-2005 models: Install the throttle cable (see «THROTTLE CABLE REMOVAL/INSTALLATION»(ref-221333-S16386591022006022400000) ), then adjust the cable (see «THROTTLE CABLE ADJUSTMENT»(ref-221333-S15624127062006022400000) ).
50. Install the drive belt (see «DRIVE BELT REPLACEMENT»(ref-351946-S31110247242009122900000) ).
51. 2000-2005 models: Install the intake air cleaner housing (A), then install the harness clamps (B), connect air control solenoid valve connector (C) and vacuum hoses (D).
52. 2006-09 model: Install the intake air cleaner housing (A), then install the IAT sensor harness clamps (B).
53. 2000-2005 models: Install the air cleaner assembly (A) and air cleaner housing cover (B), then connect the air hose (C) and breather pipe (D).
54. 2006-09 model: Install the air cleaner assembly (A) and air cleaner housing cover (B), then install the MAP sensor harness (C) to the holder, connect the IAT sensor connector (D) and breather pipe (E).
55. After installation, check that all tubes, hoses, and connectors are installed correctly.
56. After assembly, wait at least 30 minutes before filling the engine with oil.
57. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
58. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
59. Refill the engine with engine oil (see «OIL PRESSURE TEST»(ref-221324-S41879893542006022400000) ).
60. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see «COOLANT REPLACEMENT»(ref-221326-S23165940062006022400000) ).
61. 2000-2005 models: Do the engine control module (ECM) idle learn procedure (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ).
62. 2006-08 model: Do the crankshaft position (CKP)/CKP learn procedure (see «HDS CLEAR COMMAND»(ref-221338-S37856226892006022400000) ).
63. Inspect the idle speed: 2000-2005 models (see «IDLE SPEED INSPECTION»(ref-221331-S09851216702006022400000) ) 2006-08 models (see «IDLE SPEED INSPECTION»(ref-221342-S10994389392006022400000) )
64. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(ref-221318-S03270425022006022400000) ).