Repair Procedure

1. Loosen the alternator mounting bolt, nut, and adjusting bolt, then remove the alternator belt.

2. Raise the vehicle on a hoist.

3. Remove the splash shield.

4. Remove the center beam.

5. Remove the through-bolt securing the front mount bracket to the front mount.

6. Remove and discard the self-locking nuts from both radius rods, then remove the front beam.

Steps 7 and 8 apply only to models equipped with A/C.

7. Remove the A/C compressor - do not disconnect the refrigerant lines from the compressor.

8. Remove the A/C compressor bracket from the engine block.

9. Remove and discard the stud that is closest to the exhaust manifold.








10. Remove exhaust pipe A.





11. Determine the length of the crack in the engine block, then mark both ends for later reference.

12. Remove and retain the flange bolt and washer that secure the exhaust manifold to the exhaust manifold bracket.

13. Remove the exhaust manifold bracket from the engine block. Discard the bracket, flange bolt, and washer.





14. Using a 90-degree die grinder (Snap-on Part No. AT110 or equivalent) with a grinding burr (Snap-on Part No. VWB308A or equivalent), grind a 1 to 1.5 mm-deep V-shaped groove along the entire length of the crack. Grind beyond the ends of the crack approximately 5 mm.

15. For good sealer adhesion, use brake cleaner to clean the area surrounding the crack, then sand the area with coarse sandpaper.

16. Apply a 4 to 5 mm wide bead of Honda Bond HT or Ultra Flange Adhesive into the V-shaped groove. Let the sealer cure for at least one hour before starting the engine.

17. Models with A/C: Reinstall the A/C compressor bracket to the engine block. Use the two flange bolts and the flange nut retained in step 8. Do not torque the bolts or the nut at this time.

18. DX without A/C: Install the A/C compressor bracket to the engine block. Use two new 10 X 30 mm flange bolts and one new 10 mm flange bolts and one new 10 mm flange nut (see PARTS INFORMATION). Do not torque the bolts or the nut at this time.





19. Install the new exhaust manifold bracket onto the A/C compressor bracket, and secure it with a new 10 x 50 mm flange bolt and a new 11 x 24 mm washer (see PARTS INFORMATION). Do not torque the bolts or the nut at this time.

20. Mount the bracket to the exhaust manifold with the flange bolt and washer retained in step 12. Do not torque the bolt at this time.

21. Torque the A/C compressor bracket flange bolts and nuts to 49 N.m (36 lb-ft), then torque the flange bolt securing the exhaust manifold to the bracket to 44 N.m (33 lb-ft).





22. Reinstall exhaust pipe A.

23. Models with A/C: Reinstall the A/C compressor. Torque the four mounting bolts to 22 N.m (16 lb-ft).

24. Reinstall the front beam. Torque the six flange bolts to 64 N.m (47 lb-ft).

25. Reinstall the radius rods with new 12 mm self-locking nuts. Torque the nuts to 54 N.m (40 lb-ft).

26. Reinstall the through-bolt to the front mount. Torque the bolt to 64 N.m (47 lb-ft).

27. Reinstall the center beam. Torque the five mounting bolts to 50 N.m (37 lb-ft).

28. Reinstall the splash shield. Torque the seven flange bolts to 9.8 N.m (7.2 lb-ft).

29. Lower the vehicle.

30. Reinstall and adjust the alternator belt. Torque the mounting nut to 22 N.m (16 lb-ft) and the mounting bolt to 44 N.m (33 lb-ft).