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Special Tools .............................................................................................................................................................. 06-2

Component Location Index ........................................................................................................................................ 06-3
Engine Compression Inspection ................................................................................................................................ 06-6
VTEC Rocker Arm Test .............................................................................................................................................. 06-7
VTC Actuator Inspection ............................................................................................................................................ 06-8
Valve Clearance Adjustment ...................................................................................................................................... 06-9
Crankshaft Pulley Removal and Installation............................................................................................................. 06-11
Cam Chain Removal ................................................................................................................................................ 06-12
Cam Chain Installation ............................................................................................................................................. 06-15
Auto-Tensioner Removal/Installation........................................................................................................................ 06-19
Chain Case Oil Seal Installation............................................................................................................................... 06-21
Cam Chain Inspection.............................................................................................................................................. 06-22
Cylinder Head Cover Removal................................................................................................................................. 06-23
Cylinder Head Removal ........................................................................................................................................... 06-24
VTC Actuator, Exhaust Camshaft Sprocket Replacement ....................................................................................... 06-25
Cylinder Head Inspection for Warpage .................................................................................................................... 06-26
Rocker Arm Assembly Removal .............................................................................................................................. 06-27
Rocker Arms and Shafts Disassembly/Reassembly ................................................................................................ 06-28
Rocker Arms and Shafts Inspection ......................................................................................................................... 06-29
Camshaft Inspection ................................................................................................................................................ 06-30
Valves, Springs and Valve Seals Removal............................................................................................................... 06-32
Valve Inspection ....................................................................................................................................................... 06-33
Valve Stem-to-Guide Clearance Inspection.............................................................................................................. 06-33
Valve Guide Replacement........................................................................................................................................ 06-34
Valve Seat Reconditioning ....................................................................................................................................... 06-36
Valves, Springs and Valve Seals Installation............................................................................................................ 06-38
Rocker Arm Assembly Installation............................................................................................................................ 06-39
Cylinder Head Installation ........................................................................................................................................ 06-40
Cylinder Head Cover Installation.............................................................................................................................. 06-42
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 07HAH-PJ70100 Valve Guide Reamer, 5.525 mm 1

 07JAA-0010200 Socket Wrench, 19 mm 1
 07JAB-0010200 Handle 1
 07JAB-0010400 Pulley Holder Attachment, HEX 50 mm 1
 07LAJ-PR30101 Valve Inspection Set 1
 07ZAJ-PNA0101 VTEC Air Adapter 2
 07ZAJ-PNA0200 VTEC Air Stopper 1
 07ZAJ-PNA0300 Air Joint Adapter 1
 07ZAJ-PNA0400 Air Socket Adapter 1
 07PAD-0010000 Stem Seal Driver 1
 07742-0010100 Valve Guide Driver, 5.5 mm 1
 07746-0010400 Driver Attachment, 52 x 55 mm 1
 07749-0010000 Handle Driver 1
 07757-PJ10100 Valve Spring Compressor Attachment 1
 07757-0010000 Valve Spring Compressor 1

   

   

   

  


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Installation, page 06-42
 &$0&+$,1 Removal, page 06-12
Installation, page 06-15
Inspection, page 06-22
 &5$1.6+$)738//(< Replacement, page 06-11
 &5$1.6+$)738//(<%2/7 Replacement, page 06-11
 $8727(16,21(5 Replacement, page 06-19
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Installation, page 06-26
 (;+$867&$06+$)76352&.(7 Removal, page 06-25
Installation, page 06-26
 52&.(5$50$66(0%/< Overhaul, page 06-28
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 Warm up the engine to normal operating  Connect a tachometer.

temperature (cooling fan comes on).
 Open the throttle fully, then crank the engine with
 Turn the ignition switch OFF. the starter motor and measure the compression.
 Remove the intake manifold cover (see step 1 on &RPSUHVVLRQ3UHVVXUH

page 06-23). $ERYHNSD NJIFPðSVL USP PLQ

 Disconnect all four injector connectors.  Measure the compression on the remaining
cylinders.
 Start the engine, and let it run until it stalls.
0D[LPXPYDULDWLRQ
 Remove the four ignition coils (see page 04-21). :LWKLQN3D NJIFPðSVL

 Remove the four spark plugs.  If the compression is not within specifications,
 Attach the compression gauge to the spark plug check the following items, then remeasure the
hole. compression.
‡ Damaged or worn valves and seats
‡ Damaged cylinder head gasket
‡ Damaged or worn piston rings
‡ Damaged or worn piston and cylinder bore


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97(&5RFNHU$UP7HVW

6SHFLDO7RROV5HTXLUHG  Repeat step 3 on the remaining intake primary

‡ Valve inspection set 07LAJ-PR30101 rocker arms with each piston at TDC. When all the
‡ VTEC air adapter 07ZAJ-PNA0101 primary rocker arms pass the test, go to step 5.
‡ VTEC air stopper 07ZAJ-PNA0200
‡ Air joint adapter 07ZAJ-PNA0300
 Check that the air pressure on the shop air
‡ Air socket adapter 07ZAJ-PNA0400
compressor gauge indicates over 400 kPa (4 kgf/
cm², 57 psi).
 Remove the cylinder head cover (see page 06-23).
 Inspect the valve clearance (see page 06-9).
 Set the No. 1 piston at Top Dead Center (TDC),
 Remove the sealing bolt (A) from the relief hole,
(see step 1 on page 06-12).
and install the VTEC air stopper (B).
 Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
‡ If the intake primary rocker arm does not move,
remove the primary and secondary rocker arms as
an assembly and check that the pistons in the
secondary and primary rocker arms move smoothly.
If any rocker arm needs replacing, replace the
primary and secondary rocker arms as an
assembly, and test.
‡ If the intake primary rocker arm moves freely, go to
step 4.

 Remove the No. 2 and No. 3 camshaft holder bolts,

and install the VTEC air adapters (C) finger-tight.
 Connect the air joint adapter (D), air socket adapter
(E), and valve inspection set (F).
(cont’d)


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 Loosen the valve on the regulator, and apply the  Remove the cylinder head cover (see page 06-23).
specified air pressure.
 Remove the auto-tensioner (see page 06-19).
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N3D PNJIFPðSVL
 Loosen the rocker arm adjusting screws (see step
2 on page 06-27).
NOTE: If the synchronizing piston does not move after
applying air pressure; move the primary or secondary  Remove the camshaft holder (see step 3 on page
rocker arm up and down manually by rotating the 06-27).
crankshaft clockwise.
 Remove the intake camshaft.
 With the specified air pressure applied, move the
 Check that the Variable Valve Timing Control (VTC)
intake primary rocker arm (A) for the No. 1 cylinder.
actuator is locked by turning the VTC actuator
The primary rocker arm and secondary rocker arm
clockwise and counterclockwise. If the VTC
(B) should move together.
actuator is not locked, replace the VTC actuator.
‡ If the intake secondary rocker arm does not move,
remove the primary and secondary rocker arms as  Seal the advance holes (A) and retard holes (B) in
an assembly and check that the pistons in the the No. 1 camshaft journal with the tape.
primary and secondary rocker arms move smoothly.
If any rocker arm needs replacing, replace the
primary and secondary rocker arms as an
assembly, and test.

 Punch a hole in the tape over one of the advance

holes.

 Remove the special tools.

 Tighten the camshaft holder mounting bolts to 22
N·m (2.2 kgf·m, 16 lbf·ft).
 Tighten the sealing bolt to 20 N·m (2.0 kgf·m, 14
lbf·ft).
 Install the cylinder head cover (see page 06-42).


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 Apply air to the advance hole to release the lock. NOTE: Adjust the valves only when the cylinder head
temperature is less than 38°C (100°F).
 Remove the cylinder head cover (see page 06-23).
 Set the No. 1 piston at Top Dead Center (TDC).
The punch mark (A) marked with an arrow on the
Variable Valve Timing Control (VTC) actuator and
the punch mark (B) on the exhaust camshaft
sprocket should be at the top. Align the TDC marks
(C) on the VTC actuator and exhaust camshaft
sprocket.

 Check that the VTC actuator moves smoothly. If the

VTC actuator does not move smoothly, replace the
VTC actuator.

(cont’d)


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 Select the correct thickness feeler gauge for the  If you feel too much or too little drag, loosen the
valves you’re going to check. locknut (A), and turn the adjusting screw (B) until
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the drag on the feeler gauge is correct.
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 Tighten the locknut and recheck the clearance.

Repeat the adjustment if necessary.
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 Rotate the crankshaft 180° clockwise (camshaft

pulley turns 90°).
 Insert the feeler gauge (A) between the adjusting
screw (B) and the end of the valve stem and slide it
back and forth; you should feel a slight amount of
drag.

 Check and, if necessary, adjust the valve clearance

on No. 3 cylinder.


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 Rotate the crankshaft 180° clockwise camshaft 6SHFLDO7RROV5HTXLUHG

pulley turns 90°). ‡ Handle 07JAB-0010200
‡ Pulley holder attachment, HEX 50 mm 07JAB-0010400
‡ Socket wrench, 19 mm 07JAA-0010200

5HPRYDO
 Remove front tires/wheels.
 Remove the splash shield (see step 3 on page 06-
12).
 Hold the pulley with handle (A) and holder
attachment (B).

 Check and, if necessary, adjust the valve clearance

on No. 4 cylinder.
 Rotate the crankshaft 180°) clockwise (camshaft
pulley turns 90°).

 Remove the bolt with a 19 mm socket (C) and

breaker bar.
(cont’d)

 Check and, if necessary, adjust the valve clearance

on No. 2 cylinder.
 Install the cylinder head cover (see page 06-42).


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NOTE: Keep the cam chain away from magnetic fields.
,QVWDOODWLRQ  Turn the crankshaft pulley so its Top Dead Center
 Clean the crankshaft pulley (A), crankshaft (B), bolt (TDC) mark (A) lines up with the pointer (B).
(C), and washer (D). Lubricate as shown below.
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 Install the crankshaft pulley, and hold the pulley  Remove the front tires/wheels.
with handle (A) and holder attachment (B).
 Remove the splash shield.

 Tighten the bolt to 245 N·m (25.0 kgf·m, 181 lbf·ft)

with a torque wrench and 19 mm socket (C). Do not  Remove the drive belt (see page 04-29).
use an impact wrench.
 Remove the cylinder head cover (see page 06-23).
 Install the splash shield (see step 24 on page 06-
19).  Remove the crankshaft pulley (see page 06-11).

 Install front tires/wheels.


&\OLQGHU+HDG

 Disconnect the Crankshaft Position (CKP) sensor  Remove the side engine mount bracket.
connector (A) and Variable Valve Timing Control
(VTC) oil control solenoid valve connector (B).

 Remove the chain case.

 Remove the VTC oil control solenoid valve (see

step 1 on page 11-137).
 Support the engine with a jack and wood block
under the oil pan.
 Remove the ground cable (A), and remove the
upper bracket (B).

(cont’d)


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 Loosely install the crankshaft pulley.  Remove the auto-tensioner.
 Turn the crankshaft counterclockwise to compress
the auto-tensioner.

 Remove the cam chain guide B.

 Align the holes on the lock (A) and the auto-
tensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the pin.


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 Remove the cam chain guide A (A) and tensioner NOTE: Keep the cam chain away from magnetic fields.
arm (B).
 Set the crankshaft to Top Dead Center (TDC). Align
the TDC mark (A) on the crankshaft sprocket with
the pointer (B) on the cylinder block.

 Remove the cam chain.  Set the camshafts to TDC. The punch mark (A)
marked with an arrow on the Variable Valve Timing
Control (VTC) actuator and the punch mark (B) on
the exhaust camshaft sprocket should be at the
top. Align the TDC marks (C) on the VTC actuator
and exhaust camshaft sprocket.

(cont’d)


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 Install the cam chain on the crankshaft sprocket  Install the cam chain guide A (A) and tensioner arm
with the colored piece (A) aligned with the punch (B).
mark (B) on the crankshaft sprocket.

 Install the cam chain on the VTC actuator and

exhaust camshaft sprocket with the punch marks
(A) aligned with the two colored pieces (B).
 Install the auto-tensioner.


&\OLQGHU+HDG

 Install the cam chain guide B.  Remove old liquid gasket from the chain case
mating surfaces, bolts, and bolt holes.
 Clean and dry the chain case mating surfaces.
 Apply liquid gasket, P/N 08C70-K0234M, 08C70-
K0334M or 08C70-X0331S, evenly to the cylinder
block mating surface of the chain case and to the
inner threads of the holes.

 Remove the pin from the auto-tensioner.

Apply liquid gasket along the broken line.

 Apply liquid gasket to the cylinder block upper

surface contact areas (A) on the chain case.
 Apply liquid gasket, P/N 08C70-K0334M or 08C70-
X0331S, evenly to the oil pan mating surface of the
chain case and to the inner threads of the holes.
NOTE: Do not install the parts if 5 minutes or more
 Check the chain case oil seal for damage. If the oil have elapsed since applying liquid gasket. Instead,
seal is damaged, replace the chain case oil seal reapply liquid gasket after removing old residue.
(see page 06-21).

Apply liquid gasket along the broken line.

(cont’d)


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 Install the new O-ring (A) on the chain case. Set the  Install the side engine mount bracket.
edge of the chain case (B) to the edge of the oil pan
(C), then install the chain case on the cylinder block
(D).
NOTE: When installing the chain case, do not slide
the bottom surface on the oil pan mounting surface.

 Install the upper bracket (A), then tighten the bolt/
nuts in the numbered sequence shown.

 Install the ground cable (B).


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 Install the VTC oil control solenoid valve (see step 5HPRYDO
1 on page 11-137).
 Remove the chain case cover.
 Connect the Crankshaft Position (CKP) sensor
connector (A) and VTC oil control solenoid valve
connector (B).

 Turn the crankshaft counterclockwise to compress

the auto-tensioner.
 Install the crankshaft pulley (see page 06-11).
 Install the cylinder head cover (see page 06-42).
 Install the drive belt.
 Install the splash shield.

(cont’d)


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 Align the holes on the lock (A) and the auto-  Install the auto-tensioner.
tensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the pin.

 Remove the auto-tensioner.  Remove the pin from the auto-tensioner.


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 Remove old liquid gasket from the chain case 6SHFLDO7RROV5HTXLUHG

cover mating surfaces, bolts and bolt holes. ‡ Handle driver 07749-0010000
‡ Driver attachment, 52 x 55 mm 07746-0010400
 Clean and dry the chain case cover mating
surfaces.  Use the special tools to drive a new oil seal
 Apply liquid gasket, P/N 08C70-K0234M, 08C70- squarely into the chain case to the specified
K0334M or 08C70-X0331S, evenly to the chain installed height.
case mating surface of the chain case cover and to
the inner threads of the holes.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.

Apply liquid gasket along the broken  Measure the distance between the chain case
line. surface and oil seal.
 Install the chain case cover. 2LO6HDO,QVWDOOHG+HLJKW

PP LQ


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 Remove the front tires/wheels.  Remove old liquid gasket from the chain case
mating surfaces, bolts and bolt holes.
 Remove the splash shield (see step 3 on page 06-
12).  Clean and dry the chain case mating surfaces.
 Remove the drive belt (see page 04-30).  Apply liquid gasket, P/N 08C70-K0234M, 08C70-
K0334M or 08C70-X0331S, evenly to the cylinder
 Remove the cylinder head cover (see page 06-23).
block mating surface of the chain case and to the
 Remove the crankshaft pulley (see step 7 on page inner threads of the holes (see step 12 on page 06-
06-13). 17).
 Disconnect the Crankshaft Position (CKP) sensor  Apply liquid gasket to the cylinder block upper
connector and Variable Valve Timing Control (VTC) surface contact areas on the chain case (see step
oil control solenoid valve connector (see step 7 on 13 on page 06-17).
page 06-13).
 Apply liquid gasket, P/N 08C70-K0334M or 08C70-
 Remove the VTC oil control valve (see step 1 on X0331S, evenly to the oil pan mating surface of the
page 11-137). chain case and to the inner threads of the holes
(see step 14 on page 06-17).
 Support the engine with a jack and wood block
under the oil pan. NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
 Remove the ground cable, and remove the upper reapply liquid gasket after removing old residue.
bracket (see step 10 on page 06-13).
 Install the new O-ring on the chain case. Set the
 Remove the side engine mount bracket (see step edge of the chain case to the edge of the oil pan,
11 on page 06-13). then install the chain case on the cylinder block
(see step 15 on page 06-18).
 Remove the chain case (see step 12 on page 06-
13). NOTE: When installing the chain case, do not slide
the bottom surface on the oil pan mounting surface.
 Measure the tensioner rod length. If the length is
over the tolerance, replace the cam chain and oil  Install the side engine mount bracket (see step 16
pump chain. on page 06-18).
7HQVLRQHU5RG/HQJWK  Install the upper bracket and the ground cable (see
6HUYLFH/LPLW PP LQ step 17 on page 06-18).
 Install the VTC oil control solenoid valve (see page
11-137).
 Connect the CKP sensor connector and VTC oil
control solenoid valve connector (see step 20 on
page 06-19).
 Install the crankshaft pulley (see page 06-12).
 Install the cylinder head cover (see page 06-42).
 Install the drive belt.
 Install the splash shield (see step 24 on page 06-
 Check the chain case oil seal for damage. If the oil 19).
seal is damaged, replace the chain case oil seal
(see page 06-21).  Install the front tires/wheels.


&\OLQGHU+HDG

&\OLQGHU+HDG&RYHU5HPRYDO

 Remove the intake manifold cover.  Remove the cylinder head cover.

 Remove the four ignition coils (see page 04-21).

 Remove the bolt (A) securing the power steering
hose bracket.

 Remove the dipstick (B) and breather hose (C).


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NOTE:  Remove the engine wire harness connectors and

‡ Use fender covers to avoid damaging painted surfaces. wire harness clamps from the cylinder head.
‡ To avoid damage, unplug the wiring connectors carefully ‡ Four injector connectors
while holding the connector portion.
‡ Engine Coolant Temperature (ECT) sensor
‡ To avoid damaging the cylinder head, wait until the
connector
engine coolant temperature drops below 38°C (100°F)
before loosening the cylinder head bolts. ‡ Top Dead Center (TDC) sensor connector
‡ Mark all wiring and hoses to avoid misconnection. Also, ‡ Camshaft Position (CMP) sensor connector
be sure that they do not contact other wiring or hoses, or
interfere with other parts.  Remove the upper radiator hose (A) and heater
hose (B).
 Drain the engine coolant (see page 10-6).
 Relieve fuel pressure (see page 11-154).
 Disconnect the fuel feed hose (see page 11-156).
 Remove the drive belt (see page 04-30).
 Remove the intake manifold (see page 09-3).
 Remove the water bypass hose (A).

 Remove the harness holder (A) from the bracket,

then remove the connecting pipe mounting bolt (B)
and brake booster vacuum line mounting bolts (C).

 Remove the exhaust manifold (see page 09-8).

 Remove the cam chain (see page 06-12).


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97&$FWXDWRU([KDXVW&DPVKDIW6SURFNHW
5HSODFHPHQW
 Remove the rocker arm assembly (see page 06-
27). 5HPRYDO
 Remove the cylinder head bolts. To prevent  Remove the cam chain (see page 06-12).
warpage, unscrew the bolts in sequence 1/3 turn at
a time; repeat the sequence until all bolts are  Hold the camshaft with an open-end wrench, then
loosened. loosen the Variable Valve Timing Control (VTC)
actuator mounting bolt and exhaust camshaft
&</,1'(5+($'%2/76/226(1,1*6(48(1&( sprocket mounting bolt.

 Remove the cylinder head.

 Remove the VTC actuator and exhaust camshaft

sprocket.
(cont’d)


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5HSODFHPHQW FRQW¶G
 Remove the cylinder head (see page 06-24).
,QVWDOODWLRQ  Inspect the camshaft (see page 06-30).
 Install the VTC actuator and exhaust camshaft  Check the cylinder head for warpage. Measure
sprocket. along the edges, and three ways across the center.
 Apply engine oil to the threads of the VTC actuator ‡ If warpage is less than 0.05 mm (0.002 in.) cylinder
mounting bolt and exhaust camshaft mounting bolt, head resurfacing is not required.
then install them. ‡ If warpage is between 0.05 mm (0.002 in.) and 0.2
 Hold the camshaft with an open-end wrench, then mm (0.008 in.), resurface the cylinder head.
tighten the bolts. ‡ Maximum resurface limit is 0.2 mm (0.008 in.)
6SHFLILHGWRUTXH
based on a height of 104 mm (4.09 in.).
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 Install the cam chain (see page 06-15).


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 Remove the cam chain (see page 06-12).  Remove the cam chain guide B, camshaft holders,
and camshafts.
 Loosen the rocker arm adjusting screws (A).
 Insert the bolts (A) into the rocker shaft holder, then
remove the rocker arm assembly (B).

 Remove the camshaft holder bolts. To prevent

damaging the camshafts, unscrew the bolts two
turns at a time, in a crisscross pattern.

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NOTE:
‡ Identify parts as they are removed to ensure reinstallation in original location.
‡ Inspect the rocker shafts and rocker arms (see page 06-29).
‡ The rocker arms must be installed in the same positions if reused.
‡ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
holders, springs and rocker arms on the shaft.
‡ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points.
‡ Bundle the rocker arms with rubber bands to keep them together as a set.

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 Remove the rocker arm assembly (see page 06-  Measure the inside diameter of the rocker arm, and
27). check it for an out-of-round condition.
 Measure the diameter of the shaft at the first rocker 5RFNHU$UPWR6KDIW&OHDUDQFH

location. 6WDQGDUG 1HZ 

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 Zero the gauge (A) to the shaft diameter.

 Repeat for all rocker arms and both shafts. If the

clearance is over the limit, replace the rocker shaft
and all overtolerance rocker arms. If any VTEC
rocker arm needs replacement, replace rocker
arms (primary and secondary) as a set.
(cont’d)


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 Inspect the rocker arm pistons (A). Push each NOTE: Do not rotate the camshaft during inspection.
piston manually.
 Remove the rocker arm assembly (see page 06-
If it does not move smoothly, replace the rocker
27).
arm set.
NOTE: Apply oil to the pistons when reassembling.  Put the rocker shaft holders, camshaft and
camshaft holders on the cylinder head, then tighten
the bolts to the specified torque.
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 Seat the camshaft by pushing it away from the  Unscrew the camshaft holder bolts two turns at a
camshaft pulley end of the cylinder head. time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
 Zero the dial indicator against the end of the
camshaft, then push the camshaft back and forth  Lift the camshafts out of the cylinder head, wipe
and read the end play. If the end play is beyond the them clean, then inspect the lift ramps. Replace the
service limit, replace the cylinder head and camshaft if any lobes are pitted, scored, or
recheck. If it is still beyond the service limit, replace excessively worn.
the camshaft.
 Clean the camshaft journal surfaces in the cylinder
&DPVKDIW(QG3OD\ head, then set the camshafts back in place. Place a
6WDQGDUG 1HZ  PP plastigage strip across each journal.
LQ

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 Install the camshaft holders, then tighten the bolts
to the specified torque as shown in step 2.
 Remove the camshaft holders. Measure the widest
portion of plastigage on each journal.
‡ If the camshaft-to-holder clearance is within limits,
go to step 11.
‡ 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 10.
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 Check the total runout with the camshaft supported 6SHFLDO7RROV5HTXLUHG
on V-blocks. ‡ Valve spring compressor attachment 07757-PJ10100
‡ If the total runout of the camshaft is within the ‡ Valve spring compressor 07757-0010000
service limit, replace the cylinder head. Identify the valves and valve springs as they are removed
‡ If the total runout is beyond the service limit, replace so that each item can be reinstalled in its original position.
the camshaft and recheck the camshaft-to-holder oil
clearance. If the oil clearance is still beyond the
 Remove the cylinder head (see page 06-24).
service limit, replace the cylinder head.  Using an appropriate-sized socket (A) and plastic
&DPVKDIW7RWDO5XQRXW
mallet (B), lightly tap the valve retainer to loosen
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the valve keepers.
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 Install the spring compressor. Compress the spring,

 Measure cam lobe height. and remove the valve keepers.

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PRI 33.925 mm 34.092 mm
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SEC 29.638 mm
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 Remove the valves (see page 06-32).  Remove the valves (see page 06-32).
 Measure the valve in these areas.  Slide the valve out of its guide about 10 mm, then
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measure the guide-to-stem clearance with a dial
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indicator while rocking the stem in the direction of
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normal thrust (wobble method).
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LQ reassemble using a new valve.
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‡ If the measurement with a new valve still exceeds
([KDXVW9DOYH'LPHQVLRQV the service limit, go to step 3.
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 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.
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6SHFLDO7RROV5HTXLUHG  Working from the camshaft side, use the driver and
‡ Valve guide driver, 5.5 mm 07742-0010100 an air hammer to drive the guide about 2 mm (0.1
‡ Valve guide reamer, 5.525 mm 07HAH-PJ70100 in.) towards the combustion chamber. This will
knock off some of the carbon and make removal
 Inspect valve stem-to-guide clearance (see page
easier. Hold the air hammer directly in line with the
06-33).
valve guide to prevent damaging the driver.
 As illustrated below, use a commercially available
 Turn the head over, and drive the guide out toward
air-impact valve guide driver (A) modified to fit the
the camshaft side of the head.
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.

 Select the proper replacement guides, and chill

them in the freezer section of a refrigerator for
about an hour.
 Use a hot plate or oven to evenly heat the cylinder
head to 150°C (300°F). Monitor the temperature
with a cooking thermometer. Do not get the head
hotter than 150°C (300°F); excessive heat may
loosen the valve seats.

 If a valve guide won't move, drill it out with a 8 mm

(5/16 inch) bit, then try again. Drill guides only in
extreme cases; you could damage the cylinder
head if the guide breaks.
 Remove the new guide(s) from the freezer, one at a
time, as you need them.


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 Apply a thin coat of clean engine oil to the outside  Coat both reamer and valve guide with cutting oil.
of the new valve guide. Install the guide from the
 Rotate the reamer clockwise the full length of the
camshaft side of the head; use the special tool to
valve guide bore.
drive the guide in 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.
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 Continue to rotate the reamer clockwise while

removing it from the bore.
 Thoroughly wash the guide in detergent and water
to remove any cutting residue.
 Check the clearances with a valve (see page 06-
33). Verify that a valve slides in the intake and
exhaust valve guides without exerting pressure.


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 Inspect valve stem-to-guide clearance (see page  Make one more very light pass with the 45° cutter
06-33). If the valve guides are worn, replace them to remove any possible burrs caused by the other
(see page 06-34) before cutting the valve seats. cutters.
 Renew the valve seats in the cylinder head using a 9DOYH6HDW:LGWK

valve seat cutter. 6WDQGDUG 1HZ  PP LQ

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 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.

 Carefully cut a 45° seat, removing only enough

material to ensure a smooth and concentric seat.
 Bevel the upper and lower edges at the angles
shown in the illustration.
Check the width of the seat and adjust accordingly.
 The actual valve seating surface (B), as shown by
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‡ If it is too high (closer to the valve stem), you must
make a second cut with the 67.5° 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 35° cutter (intake side)
or the 30° cutter (exhaust side) 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
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 Insert the intake and exhaust valves in the head,

and measure valve stem installed height (A).
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 If valve stem installed height is over the standard,

replace the valve and recheck. If it is still over the
standard, replace the cylinder head; the valve seat
in the head is too deep.


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6SHFLDO7RROV5HTXLUHG  Install the valve spring. Place the end of the valve
‡ Stem seal driver 07PAD-0010000 spring with closely wound coils toward the cylinder
‡ Valve spring compressor attachment 07757-PJ10100 head.
‡ Valve spring compressor 07757-0010000
 Install the valve retainer.
 Coat the valve stems with engine oil. Install the
 Install the valve spring compressor. Compress the
valves in the valve guides.
spring, and install the valve keepers.
 Check that the valves move up and down smoothly.
 Install the spring seats on the cylinder head.
 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.

 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 keepers. Tap the
NOTE: Use 5.5 mm side
valve stem only along its axis so you do not bend
the stem.


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 Clean and dry the No. 5 rocker shaft holder mating  Remove the bolts from the rocker shaft holder.
surface.
 Punch marks on the Variable Valve Timing Control
 Apply liquid gasket, P/N 08C70-K0234M, 08C70- (VTC) actuator and exhaust camshaft sprocket are
K0334M or 08C70-X0331S, evenly to the cylinder facing up, then set the camshafts (A) in the holder.
head mating surface of the No. 5 rocker shaft
holder.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.

Apply liquid gasket along the broken line.

 Reassembly the rocker arm assembly (see page  Set the camshaft holders (B) and cam chain guide
06-28). B (C) in place.
 Insert the bolts (A) into the rocker shaft holder, then  Tighten the bolts to the specified torque.
install the rocker arm assembly (B) on the cylinder 6SHFLILHGWRUTXH
head. PPEROWV 1ÂP NJIÂPOEIÂIW

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 Install the cam chain (see page 06-15), and adjust

the valve clearance (see page 06-9).


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Install the cylinder head in the reverse order of removal:  Measure the diameter of each cylinder head bolt at
point A and point B.
 Clean the cylinder head and block surface.
 Install the new cylinder head gasket (A) and dowel
pins (B) on the cylinder block. Always use a new
cylinder head gasket.

 If either diameter is less than 10.6 mm (0.42 in.),

 Set the crankshaft to Top Dead Center (TDC). Align replace the cylinder head bolt.
the TDC mark (A) on the crankshaft sprocket with
the pointer (B) on the cylinder block.

 Install the cylinder head on the block.


&\OLQGHU+HDG

 Apply engine oil to the bolt threads and under the  Install the rocker arm assembly (see page 06-39).
bolt heads of all the cylinder head bolts.
 Tighten the connecting pipe mounting bolt (A) and
 Tighten the cylinder head bolts in sequence to 39 brake booster vacuum line mounting bolts (B), then
N·m (4.0 kgf·m, 29 lbf·ft). Use a beam-type torque install the harness holder (C) on the bracket.
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 from the first step.

 Install the upper radiator hose (A) and heater hose
(B).
 After torquing, 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°.

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 Install the water bypass hose.  Thoroughly clean the head cover gasket and the
groove.
 Install the head cover gasket (A) in the groove of
the cylinder head cover (B).

 Install the intake manifold (see page 09-5).

 Install the exhaust manifold (see page 09-8).
 Install the cam chain (see page 06-15).
 Connect the fuel feed hose (see page 11-156).
 Adjust the valve clearance (see page 06-9).  Check that the mating surfaces are clean and dry.

 Install the drive belt (see page 04-30).  Apply liquid gasket, P/N 08C70-K0234M, 08C70-
K0334M or 08C70-X0331S on the chain case and
 Clean the battery posts and cable terminals with the No. 5 rocker shaft holder mating areas.
sandpaper, then assemble them and apply grease
NOTE: Do not install the parts if 5 minutes or more
to prevent corrosion.
have elapsed since applying liquid gasket. Instead,
 After installation, check that all tubes, hoses and reapply liquid gasket after removing old residue.
connectors are installed correctly.
 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.
 Refill the radiator with engine coolant, and bleed air
from the cooling system with the heater valve open
(see page 10-6).
 Inspect the idle speed (see page 11-148).
Apply liquid gasket to these
 Inspect the ignition timing (see page 04-20). Apply liquid gasket to these points.
points.


&\OLQGHU+HDG

 Set the spark plug seals (A) on the spark plug  Tighten the bolts in two or three steps. In the final
tubes. Once the cylinder head cover (B) is on the step, tighten all bolts, in sequence, to 12 N·m (1.2
cylinder head, slide the cover slightly back and kgf·m, 8.7 lbf·ft).
forth to seat the head cover gasket.

 Install the dipstick (A) and breather hose (B).

 Inspect the cover washers (C). Replace any

washer that is damaged or deteriorated.

 Tighten the bolt (C) securing the power steering

hose bracket.
(cont’d)


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 Install the four ignition coils (see page 04-21).

 Check that all tubes, hoses, and connectors are
installed correctly.
 Install the intake manifold cover.

 After assembly, wait at least 30 minutes before

filling the engine with oil.