ect HONDA CIVIC 2003 7.G Repair Manual

SPRINGRETAINER
EXHAUST VALVESEAL
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CYLINDER HEADRemoval, page 6'23Inspection, page 6-25Installation, page 6-39
EXHAUST VALVERemoval, page 6-31Installation, page 6-37
INTAKE VALVERemoval, page 6 31Installation, page 6 37
CYLINDER HEADGASKET
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He,tl E- _-/ |NTAKE VALVEY I 1.- GUIDE
U Replacement, page 6-33
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HEAT SHIELD
6-5

Cylinder Head
Engine Compression Inspection
1. Warm up the engine to normal operating
temperature (cooling fan comes on).
2. Turn the ignition switch OFF.
3. Remove the intake manifold cover (see step 1 onpage 6-22).
4, Disconnect all four injector connectors.
5. Start the engine, and let it run until it stalls.
6. Remove the iour ignition coils (see page 4-18).
7. Remove the four spark plugs.
8. Attach the compression gauge to the spark plug
note.
6-6
V,
\
9.
10.
Open the throttle fully, then crank the engine with
the starter motor and measure the compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
Measure the compression on the remaining
cylinders,
Maximum vadation
Within 200 kPa (2.0 kgf/cm', 28 psi)
lf the compression is not within specifications,
check these items, then remeasure the
compressron.
. Damaged orworn valves and seats. Damaged cylinder head gasket. Damaged or worn piston rings. Damaged orworn piston and cylinder bore
11.
\-

WEC Rocker Arms Test
Special Tools Required. Air pressure regulator 07AAJ-PNAA100. VTEC air adaoter 07ZAJ-PNAA100. WEC air stoDoer 07ZAJ-PNAA200. Air joint adapter 07ZAJ-PNAA300
1. Remove the cylinder head cover (see page 6-22).
2. Set the No. 1 piston at top dead center (TDC) (see
step 1 on page 6-12).
3. Verify that the intake primary rocker arm (A) moves
independently of the intake secondary rocker arm
(B).
. lf the intake primary rockerarm 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. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms
as an assemblv, and test.. lfthe intake primary rocker arm moves freely, go
to step 4.
6.
Repeat step 3 on the remaining intake primary
rocker arms with each piston at TDC. When all the
primary rocker arms pass the test, go to step 5.
Check that the air pressure on the shop air
compressor gauge indicates over 400 kPa
(4 kgflcm', 57 psi).
Inspect the valve clearance (see page 6-9).
Remove the sealing bolt (A)from the relief hole,
and install the VTEC air stopper (B).7.
OTAAJ.PNAAlOODOTZAJ-PNAA3OO
Remove the No. 2 and No. 3 camshaft holder bolts,
and installthe VTEC air adapters (C) finger-tight.
Connect the air joint adapter (D), and air pressure
regulator with a 0-100 psi gauge (E).
(cont'd)
OTZAJ.PNAAlOO
6-7

Cylinder Head
WEC Rocker Arms Test (cont'dl
'10. Loosen the valve on the regulator, and apply thespecified air pressure.
Specified air pressure:
290 kPa 13.0 kgt/cm', 42 psi)
NOTE: lf the synchronizing piston does not moveafter applying air pressure; move the primary orsecondary rocker arm up and down manually byrotating the crankshaft clockwise.
11. With the specified air pressure applied, move theintake primary rocker arm (A)forthe No, 1 cylinder.The primary rocker arm and secondary rocker arm(B) should move together.
lf the intake secondary rocker arm does not move,
remove the primary and secondary rocker arms asan assembly, and check that the pistons in theprimary and secondary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms asan assembly, and test.
Remove the special tools.
Tighten the camshaft holder mounting bolts lo22N m 12.2 kgf.m, 16 lbf.ft).
Tighten the sealing boltto 20 N.m (2.0 kgf.m,
14 tbf.ft).
Installthe cylinder head cover (see page 6-41).
12.
13.
14.
t5.
6-8
VTG Actuator Inspection
'11. Remove the cylinder head cover (see page 6-22lr.
2. Remove the auto-tensioner (see page 6-19).
3. Loosen the rocker arm adjusting screws lsee step 2on page 6-26).
4. Remove the camshaft holder (see step 3 on page 6-
26t.
5. Remove the intake camshaft.
6, Check that the variable valve timing control (VTC)
actuator is locked by turning the VTC actuator
clockwise and counterclockwise. lf the VTC actuatoris not locked, replace the VTC actuator.
7. Seal the advance holes (A)and retard holes (B) in
the No. 1 camshaft journal with tape.
Punch a hole through the tape over one of theadvance holes.

Gylinder Head
IValve Clearance Adjustment (cont'd)
3. Select the correct thickness feeler gauge for the
valves you're going to check.
Intake: 0.21 0.25 mm (0.008-0.010 in.)
Exhaust; 0.28 0.32 mm (0.011 0.013 in.)
Adiusting screw locations:
No. 1
EXHAUST
No. 2 No.3 No. 4
No. 1No.4
4.Insert the feeler gauge {A) between the adjusting
screw (B) and the end ofthe valve stem, and slide it
back and forth; you should feel a slight amount of
d rag.
6-10
\.
5. lf you feel toomuchortoolittledrag, loosenthe
locknut (A), and turn the adjusting screw {B) until
the drag on the feeler gauge is correct. .
Tighten the locknut, and recheck the clearance.
Repeat the adjustment if necessary
Rotate the crankshaft 180" clockwise (camshaft
pulley turns 90').
7.
t.\-
8. Check and, if necessary, adjust the valve clearance
on No. 3 cylinder.

7. Disconnectthe crankshaft position (CKP) sensor
connector {A) and variable valve timing control
{VTC) oil control solenoid valve connector (B).
Remove the VTC oil control solenoid valve (see
step 1 on page 11-127).
Support the engine with a iack and wood block
under the oil pan.
Remove the ground cable (A). and remove the
upper bracket (B).
9.
10.
11. Remove the side engine mount bracket.
12. Remove the chain case.
(cont'd)
6-13

19.
20.
lnstall the variable valve timing control (VTC) oil
control solenoid valve (see step 1 on page 11'127).
Connect the crankshaft position (CKP) sensor
connector {A) and VTC oil control solenoid valve
connector (B).
21. Install the crankshaft pulley (see page 6-12).
22. Installthe cylinder head cover (see page 6-41).
23. Installthe drive belt.
24. Installthe splash shield.
€D@
Auto-Tensioner RemovaU
lnstallation
Removal:
1. Remove the chain case cover.
Turn the crankshaft counterclockwise to compress
the auto-tensroner.
{cont'd)
6-19

Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore 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.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

Installation:
1. Install the VTC actuator and exhaust camshaft
sprocket.
2. Apply engine oil to the th reads of the VTC actuato r
mounting bolt and exhaust camshaft mounting bolt,
then install them.
3. Hold the camshaft with an open-end wrench, then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
113 N.m (11.5 kgl.m,83 lbl.ft)
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
4. Install the cam chain {see page 6-15).
1,
Cylinder Head Inspection for
Warpage
Remove the cylinder head {see page 6-23).
Inspect the camshaft (see page 6-29).
Check the cylinder head for warpage. Measure
along the edges, and three ways across the center.
. lf warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacing is not required.. lf 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 104 mm (4.09 in.).
Cylinder Head Height;
Standard {New}: 103.95 104.05 mm
{4.093 4.096 in.}
6-25

NOTE:
Rocker Arms and Shafts Disassembly/Reassembly
ldentify parts as they are removed to ensure reinstallation in original location.
Inspect the rocker shafts and rocker arms (see page 6-28).
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 keeD them tooether as a set.
EXHAUST ROCKERSHAFT
EXHAUST ROCKER ARM
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INTAKE ROCKERARM ASSEMBLY
INTAKE ROCKER SHAFT
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6-27