Cylinder Head Installation
Cylinder Head Installation
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 inch), 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 (8).
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 Nm (3.0 kgf-m, 22 ft. lbs.). 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 Nm (2.2 kgf-m, 16 ft. lbs.).
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 Nm (1.3 kgf-m, 9.4 ft. lbs.).
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 Nm (2.2 kgf-m, 16 ft. lbs.). 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.
31. Install the cylinder head cover.
32. Install the intake manifold (A) with a new gasket (B), then install the intake manifold stay.
33. 2000-2005 models: Install the injectors.
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 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 model)
^ Manifold absolute pressure (MAP) sensor connector
^ Primary heated oxygen sensor (primary H02S) connector (2000-2005 models)
^ A/F sensor connector (2006 model)
^ Engine coolant temperature (ECT) sensor connector (2000-2005 models)
^ Engine coolant temperature (ECT) sensor 1 connector (2006 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.
43. 2000-2005 models: Install the air hose (A), and tighten the bolt (B) securing the intake manifold bracket.
44. 2006 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 model: Install the brake booster vacuum hose (A) and fuel feed hose (B), then quick-connect fitting cover (C).
48. 2006 model: Install the intake manifold cover.
49. 2000-2005 models: Install the throttle cable, then adjust the cable.
50. Install the drive belt.
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 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 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.
60. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
61. 2000-2005 models: Do the engine control module (ECM) idle learn procedure.
62. 2006 model: Do the crankshaft position (CKP)/CKP learn procedure.
63. Inspect the idle speed.
64. Inspect the ignition timing.
65. Enter the anti-theft code for the radio, then enter the audio presets.
66. Set the clock.