ect HONDA CIVIC 2003 7.G Manual PDF

Cylinder Head
1.
2.
Rocker Arms and Shafts Inspection
Remove the rocker arm assembly (see page 6-26).
Measure the diameter of the shaft at the first rocker
location.
3. Zero the gauge (A) to the shaft diameter.
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4. Measure the inside diameter ofthe rocker arm, and
check it for an out-of-round condition.
Rocker Arm-to-Shaflt Clearance:
Standard lNew):
lntake: 0.025 0.052 mm(0.0010 0.0020 in.)
Exhaust: 0.018 0.056 mm
(0.0007 0.0022 in.)
Service Limit: 0.08 mm (0.003 in.)
5. Repeat for all rockerarms and both shafts. lfthe
clearance is over the Ilmit. replace the rocker shaft
and all overtolerance rocker arms. lf any VTEC
rocker arm needs replacement, replace the rocker
arms (primary and secondary) as a set.
6. Inspect the rocker arm pistons {A}. Push each
piston manually.
lf it does not move smoothly, replace the rocker
arm set.
NOTE: Apply oil to the pistons when reassembling.
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Gamshaft Inspection
NOTE: Do not rotate the camshaft during inspection.
1. Remove the rocker arm assembly (see page 6-26).
and disassemble it (see page 6-27).
2. Put the rocker shaft holders, camshaft, and
camshaft holders on the cylinder head, then tighten
the bolts to the specified torque.
Specified torque:
I mm bolis:
22 N.m {2.2 kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2 kgf.m,8.7 tbf.ftl
6 mm bolts: @, €0, @
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3. Seat the camshaft by pushing it away from the
camshaft pulley end ofthe cylinder head.
4. Zero the dial indicator against the end of the
camshaft, then push the camshaft back and forth
and read the end play. lf the end play is beyond the
service limit, replace the camshaft head and
recheck. lf it is still beyond the service limit, replace
the cylinder.
Camshaft End Play:
Standard {New}: 0.05 0.20 mm(0.002 0.008 in.l
Service Limit: 0.4 mm (0.02 in.)
(cont'd)
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Cylinder Head
Camshaft Inspection (cont'dl
1.
9.
Unscrew the camshaft holder bolts two turns at a
time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
Lift the camshafts out of the cylinder head, wipe
them clean. then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn,
Clean the camshaft journal surfaces in the cylinder
head, then set the camshafts back in place. Place a
plastigage strip across each journal.
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.
. lf the camshaft-to-holder clearance is within
limits, go to step 1 1.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has been replaced,
replace the cylinder head.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has not been
replaced, go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
No.2,3,4,5 Journals:
Service Limit:
0.030 0.069 mm
{0.001 0.003 in-)
0.060*0.099 mm
{0.002 0.004 in.)
0.15 mm {0.006 in.)
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10. Check the total runout with the camshaft supported
on V-blocks,
.lfthetotal runout of the camshaft is within the
service limit, replace the cylinder head.. lf the total runout is beyond the service limit,
replace the camshaft and recheck the camshaft-
to-holder oil clearance. lf the oil clearance is still
beyond the service limit, replace the cylinder
neao.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm {0.002 in.)
11. Measure cam lobe height.
Cam
PRI: Primary
C/C: Cam Chain
SEC: Secondary
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Lobe Heioht Standard (New
INTAKEEXHAUST
PRI33.925 mm(1.3356 in.)
34.092 mm
\1 .3422 in.l
SEC29.638 mm(1.1668 in.)

Gylinder Head
Valve Inspection
1.Remove the valves (see page 6-31),
Measure the valve in these areas.
lntake Valve Dimensions
A Standard lNewl: 34.85 35.15 mm
B Standard {Newl:
C Standard lNew):
C Service Limit:
B Standard (New):
C Standard (New):
C Service Limit:
Exhaust Valve Dimensions
A Standard (New): 29.85-30.15 mm
{1.372 1.384 in.l
108.7 - 109.5 mm
14.280- 4.311 in.)
5.475 5.485 mm
10.2156-0.2159 in.)
5.445 mm {0.214 in.l
(1.175- 1.187 in.)
108.3 109.1 mm
(4.264- 4.295 in.l
5.450 5.460 mm(0.2146 0.2150 in.)
5.42 mm (0.213 in.)
2.
.<
6-32
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Valve Stem-to-Guide Clearance\
Inspection
1.Remove the valves (see page 6-3'1).
Slide the valve out of its guide about 10 mm. then
measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust (wobble method).. lf the measurement exceedsthe service limit,
recheck it using a new valve.. lf the measurement is nowwithin the service
limit, reassemble using a new valve.. lf the measurementwith a newvalve still
exceeds the service limit, go to step 3.
lntake Valve Stem-to-Guide Clearance:
Standard lNew): 0.06 0.11 mm
{0.002 0.004 in.}
Service Limil: 0.16 mm {0.006 in.)
Exhaust Valve Stem-to-Guide Clearance:
Standard lNewl:0.11 -0.16 mm
10.004 0.006 in.)
Service Limit: 0.22 mm 10.009 in.)
Subtract the O.D. of the valve stem. measured with
a micrometer, from the LD. 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
lntake Valve Stem-to-Guide Clearance:
Standard (New): 0.030 0.055 mm
{0.0012 0.0022 in.)
Service Limit; 0.08 mm (0.003 in.l
Exhaust Valve Stem-to-Guide Clearance:
Standard {Newl: 0.055 0.080 mm(0.0022-0.003r in.l
Service Limit: 0.11 mm (0.004 in.)
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3.
4,.
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Valve Guide Replacement
Special Tools Required. Valve guide driver, 5.5 mm 07742-0010100. Valve guide reamer, 5.5 mm 07HAH-PJ7o108
1.Inspect valve stem-to-guide clearance (see page 6-
32t.
As illustrated below, use a commercially available
air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.
10.8 mm{0.,|2 in.)
3. Select the proper replacement guides, and chill
lhem in the freezer section of a refriqerator for
about an hour.
4. Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"C). Monitor the temperature
with a cooking thermometer. Do not getthe head
hotterthan 300'F (150"C); excessive heat may
loosen the valve seats.
-_|Jfillr-.-4fi'11., -
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7.
Working from the camshaft side. use the driver and
an aar hammerto drive the guide about 2 mm (0.1
in.)towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn lhe head over, and drive the guide out toward
the camshaft side of the head.
lf a valve guide won't move, drill it out with a I 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 vou need them.
(cont'd)
6-33

Valve Seat Reconditioning
1. Inspect valve stem-to-guide clearance (see page 6-
32). lf the valve guides are worn, replace them (see
page 6-33) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a
valve seat cutter.
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.
INTAKE:35"EXHAUST:30'
3,
4.
- 45'
, { 67.5'
5. Make one more very light pass with the 45" cutter
to remove any possible burrs caused by the other
cutters.
Valve Seat Width:
Standard (New): 1.25 1.55 mm {0.049 0.061 in.)
Service Limit: 2.00 mm (0.079 in.)
6. 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 trmes.
1.The actual valve seating surface (B), as shown by
the blue compound, should be centered on the seat.
. lf 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.. lf it is too low (close to the valve edge), you must
make a second cut with the 35'cutter (intake
sidel 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 45'cutter.
(cont'd)
6-35

Cylinder Head
8.
Cylinder Head lnstallation (cont'd)
7.Apply engine oil to the bolt threads and under thebolt heads of all the cylinder head bolts.
Tighten the cylinder head bolts in sequence to 39N.m {4.0 kgf.m, 29 lbf.ft). Use a beam-type torquewrench. When using a preset-type torque wrench,be sure to tighten slowly and do not overtighten. lf
a bolt makes any noise while you are torquing it,
loosen the bolt and retighten it from the first step.
9.After torquing, tighten all cylinder head bolts in twosteps (90" per step). lf you are using a new cylinderhead bolt, tighten the bolt an extra 90..
FIRST STEP
SECOND STEP
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10. Installthe rocker arm assembly {see page 6-38).
1't .Install the water bypass hose (A).
---l.-.
B6x1.0mm'r2 N.m(1.2 kgl.m,8.7 lbf.ftl
12.
't3.
c6xl.0mm'12 N,m (1.2 kgt.m,8.7 lbf.ft)
Tighten the connecting pipe mounting bolt (B) andbrake booster vacuum line mounting bolts (C), theninstallthe harness holder (D) on the bracket.
Installthe upper radiator hose {A) and heater hose(B).

14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel leaks. Turn the ignition switch ON
{ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
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.
(cont'd)
6-41

Gylinder Head
Cylinder Head Gover Installation (cont'd)
Set the spark plug seals (A) on the spark plug tubes.
Once the cylinder head cover (B) is on the cylinderhead, slide the cover slightly back and forth to seat
the head cover gasket.
Inspect the cover washers (C). Replace any washer
that is damaged or deteriorated.
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7. Tighten the bolts in two or three steps. In the final
step, tighten all bolts, in sequence, to 9.8 N.m (1.0
kgf.m, 7.2 lbf.ft).
8. Install the dipstick (A) and breather hose iB).
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9.
10.
Install the four ignition coils (see page 4-'18).
Check that all tubes, hoses, and connectors are
installed correctly.
lnstallthe intake manifold cover.11.
6x 1,0 mm'12 N.m {1.2 kgf m.8.7 tbf.ftl
12. After assemblv, wait at least 30 minutes before
filling the engine with oil.
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