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 in.), replace the cylinder head bolt.

2. Clean and dry the cylinder head, the engine block, and the 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 the 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 the 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 click-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. Apply new engine oil to the cam chain sprocket mounting bolts threads. Assemble the idler gear (A) and the 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 the 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 cam chain sprocket assembly 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 assembly 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 the 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. Adjustments

31. Install the cylinder head cover. Cylinder Head Cover Installation






32. Install the intake manifold (A) with a new gasket (B), then install the intake manifold bracket (C).

33. '00-05 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. '00-05 models: Connect the water bypass hose (A), and tighten the two bolts (B) securing the intake manifold bracket.






40. '06-09 models: Install the intake manifold bracket (A), then connect the evaporative emission (EVAP) hose (B) and the water bypass hose (C), install the wire harness clamp (D) and the bracket (E).

41. Connect the following 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 ('00-05 models)

- Idle air control (IAC) valve connector ('00-05 models)

- Throttle position (TP) sensor connector ('00-05 models)

- Throttle body connector ('06-09 models)

- Manifold absolute pressure (MAP) sensor connector

- Primary heated oxygen sensor (primary HO2S) connector ('00-05 models)

- A/F sensor connector ('06-09 models)

- Engine coolant temperature (ECT) sensor connector ('00-05 models)

- Engine coolant temperature (ECT) sensor 1 connector ('06-09 models)

- Rocker arm oil control valve (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. '00-05 models: Connect the air hose (A), and tighten the bolt (B) securing the intake manifold bracket.






44. '06-09 models: Install the bolt (A) securing the intake manifold bracket.






45. Connect the evaporative emission (EVAP) canister hose.

'00-05 models





'06-09 models





46. '00-05 models: Connect the brake booster vacuum hose (A), the fuel return hose (B), and the fuel feed hose (C), using new washers (D).

'00-03 models





'04-05 models





47. '06-09 models: Connect the fuel feed hose (A), then install the quick-connect fitting cover (B), and connect the brake booster vacuum hose (C).






48. '06-09 models: Install the intake manifold cover.

49. '00-05 models: Install the throttle cable, then adjust the cable.

50. Install the drive belt. Testing and Inspection






51. '00-05 models: Install the air cleaner housing (A), then install the harness clamps (B), connect the air control solenoid valve connector (C) and the vacuum hoses (D).






52. '06-09 models: Install the air cleaner housing (A), then install the IAT sensor harness clamps (B).






53. '00-05 models: Install the air cleaner assembly (A) and the air cleaner housing cover (B), then connect the air hose (C) and the breather pipe (D).






54. '06-09 models: 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 the 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. Do the battery terminal reconnection procedure. Procedures

58. Inspect for fuel leaks. Turn the ignition switch to 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 three times, then check for fuel leakage at any point in the fuel line.

59. Refill the engine with the recommended engine oil. Service and Repair

60. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open. Service and Repair

61. '00-05 models: Do the engine control module (ECM) idle learn procedure.

62. '06-09 models: Do the crankshaft position (CKP)/CKP learn procedure. Initial Inspection and Diagnostic Overview

63. Inspect the idle speed:
- '00-05 models

- '06-09 models Testing and Inspection

64. Inspect the ignition timing. Testing and Inspection