Honda Civic manuals

Honda Civic Service Manual: Cylinder Head Inspection for Warpage (K24Z7)

Honda Civic Service Manual / Powertrain / Engine / Engine Block / Cylinder Head / Cylinder Head Inspection for Warpage (K24Z7)

1. Vehicle Lift

1.

Raise the vehicle on a lift, and make sure it is securely supported.


2. Splash Shield

1.

Remove the splash shield (A).


3. Radiator Cap

1.

Wait until the engine is cool, then carefully remove the radiator cap.


4. Radiator Coolant - Replacement

1.

Loosen the drain plug (A), and drain the coolant.


5. Fuel Filler Cap

1.

Remove the fuel fill cap to relieve the pressure in the fuel tank.


6. HDS DLC - Connection


NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


7. Fuel Pump Off

1.

Turn the ignition switch to ON (II).


2.

From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.


NOTE:

Do not allow the engine to idle above 1,000 rpm or the ECM/PCM will continue to operate the fuel pump.

Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.


3.

Turn the ignition switch to LOCK (0).


8. Battery Terminal - Disconnection


1.

Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode.


2.

Disconnect and isolate the negative cable with the battery sensor (A) from the battery.


NOTE:

Always disconnect the negative side first.

To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal.

Do not disconnect the battery sensor from the negative terminal (C).


3.

Disconnect the positive cable (D) from the battery.


9. Fuel Pressure - Relieving

1.

Remove the bracket (A).



2.

Remove the quick-connect fitting cover (A).


3.

Check the fuel quick-connect fitting for dirt, and clean it if needed.


4.

Place a rag or shop towel over the quick-connect fitting (A).


5.

Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.


NOTE:

Be careful not to damage the line (D) or other parts.

Do not use tools.

If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.

Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.


10. Air Cleaner Assembly


1.

Disconnect the intake air duct (A) and the intake air pipe (B).


2.

Remove the harness clamp (C).


3.

Remove the air cleaner (D).


11. Drive Belt

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1.

Move the auto-tensioner (A) using the belt tension release tool in the direction of the arrow to relieve tension from the drive belt, then remove the drive belt.


12. Engine Cover

1.

Remove the engine cover.


13. Intake Air Duct

1.

Remove the intake air duct.


14. Throttle Body - Removal

1.

Disconnect the EVAP canister hose (A) and the brake booster vacuum hose (B).



2.

Disconnect the connector (A).


3.

Remove the harness clamps (B).


4.

Remove the throttle body without disconnecting the hoses.


15. Intake Manifold Assembly

1.

Remove the intake manifold bracket.


2.

Remove the intake manifold (A).


3.

Disconnect the PCV hose (A).


16. Ignition Coil Harness - Move


1.

Disconnect the connectors.


2.

Move the engine harness holder (A).


17. Fuel Injector and Rail Assembly


1.

Disconnect the quick-connect fitting (A).


2.

Remove the injectors and fuel rail (B) together.


18. Injector Base Assembly

1.

Remove the injector base (A).


19. Wiper Arm Assembly


NOTE: Set the wiper arms to the auto-stop position before removal.


1.

Remove the cowl top wiper covers (A).


2.

Remove the wiper arms (B).


20. Both Side Cowl Covers


1.

Remove the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


21. Center Cowl Cover


1.

Remove the center cowl cover (A).


2.

Disconnect the windshield washer tube (B).


3.

If necessary, remove the hood rear seal (C).


22. Under Cowl Panel

1.

Remove the under cowl panel (A).


23. Engine Peripheral Hose - Disconnection

1.

Disconnect the EVAP canister hose (A) and the brake booster vacuum hose (B).


24. Rocker Arm Oil Control Valve


1.

Remove the rocker arm oil control valve assembly (A) and the rocker arm oil control valve filter (B).


2.

Remove the engine wire harness bracket (C).


25. A/F Sensor

1.

Disconnect the connector.


2.

Remove the A/F sensor (A).


26. WU-TWC


1.

Remove the WU-TWC (A).


2.

Remove the WU-TWC cover (B).


27. Heater Hose - Disconnection Engine Side

1.

Disconnect the upper radiator hose (A) and the heater hoses (B).


28. Cylinder Head Peripheral Assembly

1.

Remove the the EVAP canister purge valve bracket (A).


29. Tire and Wheel-Removal, Front Right

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1.

Remove the right front wheel.


30. Ignition Coil Cover

1.

Remove the ignition coil cover.


31. Ignition Coil

1.

Remove the ignition coils.


32. Cylinder Head Cover

1.

Remove the cylinder head cover.


33. Set The Crankshaft To Top Dead Center

1.

Turn the crankshaft so its white mark (A) lines up with the pointer (B).


NOTE: The other pointer (C) is not used.


34. Cam Chain Case Peripheral Assembly

1.

Remove the harness clamp.


35. VTC Oil Control Solenoid Valve


1.

Remove the ground cable (A).


2.

Remove the VTC oil control solenoid valve (B).


36. Crankshaft Pulley

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1.

Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).


2.

Remove the bolt with a socket, 19 mm (C) and a breaker bar, then remove the crankshaft pulley.


37. Engine Jack Support (State Of A Low Vehicle)

1.

Lift and support the engine with a jack and a wood block under the oil pan.


38. Upper Torque Rod

1.

Remove the upper torque rod.


39. Side Engine Mount

1.

Remove the ground cable (A), the side engine mount bracket (B), and the side engine mount (C).


40. Side Engine Mount Bracket, Engine Side

1.

Remove the side engine mount bracket.


41. Cam Chain Case

1.

Remove the cam chain case (A) and the spacer (B).


42. Cam Chain Auto-Tensioner


1.

Loosely install the crankshaft pulley.


2.

Turn the crankshaft counterclockwise to compress the auto-tensioner.


3.

Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.


NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.


4.

Remove the auto-tensioner.


43. Cam Chain Tensioner Arm and Cam Chain Guide

1.

Remove cam chain guide B.


2.

Remove cam chain guide A and the tensioner arm (B).


44. Cam Chain

1.

Remove the cam chain.


45. Camshaft Holder

1.

Loosen the rocker arm and the adjusting screws (A).


2.

Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.


3.

Remove cam chain guide B , the camshaft holders (A).


46. Camshaft

1.

Remove the camshafts (A).


47. Rocker Arm Assembly

1.

Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).


48. Cylinder Head Assembly


1.

Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.


2.

Remove the cylinder head.


49. Rocker Arm Assembly - Disassembly

NOTE:

Identify parts as they are removed so they can be reinstalled in their original locations.

Inspect the rocker arm shaft and rocker arms.

If reused, the rocker arms must be installed in their original location.

When removing, or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders and the rocker arms on the shaft.

Bundle the intake rocker arms with rubber bands to keep them together as a set, and remove the bands after the intake rocker arms have been installed.

When replacing the intake rocker arm assembly, remove the fastening hardware from the new intake rocker arm assembly.

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1. Camshaft - Inspection


1.

Put the rocker shaft holders, the camshaft, and the camshaft holders on the cylinder head, then tighten the bolts, in sequence, to the specified torque.


NOTE: If the engine does not have bolt , skip it and continue the torque sequence.


Specified Torque

8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

6 x 1.0 mm 12 N·m (1.2 kgf·m, 9 lbf·ft)

6 x 1.0 mm Bolts: ,


2.

Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head.


3.

Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth, and read the end play. If the end play is beyond the service limit, replace the cylinder head and recheck. If it is still beyond the service limit, replace the camshaft.


Camshaft End Play

Standard (New):

0.05-0.20 mm (0.0020-0.0079 in)

Service Limit:

0.4 mm (0.0157 in)



4.

Loosen the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.


5.

Lift the camshafts out of the cylinder head, and wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.


6.

Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.


7.

Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 1.


8.

Remove the camshaft holders. Measure the widest portion of plastigage on each journal:


If the camshaft-to-holder clearance is within the service limits, go to step 10.

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 9.


Camshaft-to-Holder Oil Clearance

Standard (New):

No. 1 Journal:

0.030-0.069 mm (0.00118-0.00272 in)

No. 2, 3, 4, 5 Journals:

0.060-0.099 mm (0.00236-0.00390 in)

Service Limit:

0.15 mm (0.00591 in)


9.

Check the total runout with the camshaft supported on V-blocks:


If the total runout of the camshaft is within the standard, replace the cylinder head.

If the total runout is beyond the standard, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the standard, replace the cylinder head.


Camshaft Total Runout

Standard (New):

0.03 mm (0.0012 in) max.


10.

Measure cam lobe height.


Cam Lobe Height Standard (New):

 

INTAKE

EXHAUST

PRI

33.744 mm
(1.32850 in)

34.291 mm
(1.35004 in)

MID

35.456 mm
(35.456 in)

SEC

33.744 mm
(1.32850 in)


PRI: Primary

MID: Mid

SEC: Secondary

C/C: Cam Chain

   

mm


2. Cylinder Head - Inspection for Warpage

1.

Check the cylinder head for warpage. Measure along the edges, and three ways across the center:


Cylinder Head Warpage

Standard (New):

0.05 mm (0.002 in) max.


If warpage is less than 0.05 mm (0.002 in) cylinder head resurfacing is not required.

Maximum resurface limited to the cylinder head height standard as shown.


Cylinder Head Height

Standard (New):

103.95-104.05 mm (4.0925-4.0964 in)



1. Rocker Arm Assembly - Reassembly

NOTE:

Identify parts as they are removed so they can be reinstalled in their original locations.

If reused, the rocker arms must be installed in their original location.

When removing, or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders and the rocker arms on the shaft.

Bundle the intake rocker arms with rubber bands to keep them together as a set, and remove the bands after the intake rocker arms have been installed.

Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to all contact points.

When replacing the intake rocker arm assembly, remove the fastening hardware from the new intake rocker arm assembly.

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2. Set The Crankshaft To Top Dead Center

1.

Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.


3. Cylinder Head Assembly

1.

Install a new coolant separator (A) in the engine block whenever the engine block is replaced.



2.

Clean the cylinder head and the engine block surface.


3.

Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.


4.

Install the cylinder head on the engine block.



5.

Measure the diameter of each cylinder head bolt at point A and point B.


6.

If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.


7.

Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.


8.

Torque the cylinder head bolts in sequence to 39 N·m (4.0 kgf·m, 29 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 from the first step.


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9.

After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 8. If you are using a new cylinder head bolt, tighten the bolt an extra 90 °.


NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.


4. Rocker Arm Assembly

2.5mm


1.

Clean and dry the No. 5 rocker shaft holder mating surface.


2.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the cylinder head mating surface of the No. 5 rocker shaft holder and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


NOTE:

Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.



3.

Install the lost motion assemblies (A) in the cylinder head.


NOTE: Apply new engine oil to the lost motion assembly.


4.

Insert the bolts (B) into the rocker shaft holder, then install the rocker arm assembly (C) on the cylinder head.


5.

Remove the bolts from the rocker shaft holder.


5. Camshaft

1.

Make sure the punch marks on the VTC actuator and the exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. Apply new engine oil to the camshaft journals and lobes.


6. Camshaft Holder

1.

Set the camshaft holders (A) and cam chain guide B in place.


2.

Tighten the bolts to the specified torque.


Specified Torque

8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

6 x 1.0 mm 12 N·m (1.2 kgf·m, 9 lbf·ft)

6 x 1.0 mm Bolts: ,


7. Cam Chain


1.

To hold the intake camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate A and through the No. 5 rocker shaft holder (D).


2.

To hold the exhaust camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate B and through the No. 5 rocker shaft holder (D).


3.

Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket.


4.

Install the cam chain on the VTC actuator and the exhaust camshaft sprocket with the punch marks (A) aligned with the center of the two colored link plates (B).


8. Cam Chain Tensioner Arm and Cam Chain Guide

1.

Install cam chain guide A and the tensioner arm (B).


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2.

Install cam chain guide B.


9. Cam Chain Auto-Tensioner

1.

Compress the auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.2 mm (3/64 in) diameter pin back into the holes (F).


NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.


2.

Install the auto-tensioner.


3.

Remove the pin from the auto-tensioner.


4.

Remove the camshaft lock pin set.


10. Cam Chain Case


1.

Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.


2.

Remove the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.


3.

Clean and dry the chain case mating surfaces.


4.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the chain case and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A) and (B).

Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (C).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


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5.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the chain case, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


NOTE:

Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).

Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (B).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


6.

Install the spacer (A), then install a new O-ring (B) on the chain case. Set the edge of the chain case (C) to the edge of the oil pan (D), then install the chain case on the engine block (E). Wipe off the excess liquid gasket on the oil pan and the chain case mating area.


NOTE:

When installing the chain case, do not slide the bottom surface onto the oil pan mounting surface.

Wait at least 30 minutes before filling the engine with oil.

Do not run the engine for at least 3 hours after installing the chain case.

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11. Side Engine Mount Bracket, Engine Side

1.

Install the side engine mount bracket (A), then tighten the side engine mount bracket mounting bolts.


12. Side Engine Mount

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1.

Install the new side engine mount mounting bolts (A) and the side engine mount bracket (B) using a nut and a new bolt, then loosely install the new side engine mount bracket mounting bolts and nut (C).


2.

Install the ground cable (D).


13. Transmission Mount - Loosen

1.

Loosen the transmission mount bracket bolt and nuts (A).


14. Lower Torque Rod Mounting Bolt - Loosen

1.

Loosen the lower torque rod mounting bolt (A).


15. Side Engine Mount - Tighten

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1.

Tighten the side engine mount bracket mounting bolt and nut.


16. Transmission Mount - Tighten

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1.

Tighten the transmission mount bracket mounting bolt and nuts.


17. Lower Torque Rod Mounting Bolt - Tighten


1.

Loosen the lower torque mount mounting bolt.


2.

Tighten the lower torque rod mount mounting bolts in the numbered sequence shown.


18. Upper Torque Rod

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1.

Install the upper torque rod using new bolts.


2.

Tighten the upper torque rod mounting bolts in the numbered sequence shown.


19. Crankshaft Pulley

1.

Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). Lubricate with new engine oil as shown.


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2.

Install the crankshaft pulley, and hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).


3.

Torque the bolt to 50 N·m (5.1 kgf·m, 37 lbf·ft) with a torque wrench and a socket, 19mm(C). Do not use an impact wrench. If the pulley bolt or crankshaft are new, torque the bolt to 177 N·m (18.0 kgf·m, 131 lbf·ft), then remove the bolt and torque it to 50 N·m (5.1 kgf·m, 37 lbf·ft).


4.

Tighten the pulley bolt an additional 90 °.


20. VTC Oil Control Solenoid Valve


1.

Install the VTC oil control solenoid valve (A) with a new O-ring (B).


NOTE:

Coat a new O-ring with engine oil.

Clean and dry the mating surface of the valve.


2.

Install the ground cable (C).


21. Cam Chain Case Peripheral Assembly

1.

Install the harness clamp.


22. Valve Clearance - Adjustment

1.

Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the 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 the exhaust camshaft sprocket.


2.

Select the correct feeler gauge for the valve clearance you are going to check.


Valve Clearance

Intake:

0.21-0.25 mm (0.009-0.009 in)

Exhaust:

0.25-0.29 mm (0.010-0.011 in)


3.

Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No.1 cylinder, and slide it back and forth; you should feel a slight amount of drag.



4.

If you feel too much or too little drag, loosen the locknut with the locknut wrench and the adjuster, and turn the adjusting screw until the drag on the feeler gauge is correct.


5.

Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.


Specified Torque

7 x 0.75 mm

14 N·m (1.4 kgf·m, 10 lbf·ft)

Apply new engine oil to the nut threads.



6.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).


7.

Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.



8.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).


9.

Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.



10.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).


11.

Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.


23. Cylinder Head Cover


1.

Check the spark plug seals for damage. If any seals are damaged, replace them.


2.

Thoroughly clean the head cover gasket and the groove.


NOTE: Check and, if necessary, replace the head cover gasket.


3.

Install the head cover gasket (A) in the groove of the cylinder head cover (B). Make sure the head cover gasket is seated securely.



4.

Remove all of the old liquid gasket from the chain case and the No.5 rocker shaft holder.


5.

Clean the head cover contacting surfaces with a shop towel.


6.

Apply liquid gasket, (P/N 08718-0004 or 08718-0009) on the chain case and the No. 5 rocker shaft holder mating areas (A). Install the component within 5 minutes of applying the liquid gasket.


NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.



7.

Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.


8.

Inspect the spark plug seals for damage.


9.

Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.


10.

Tighten the bolts in two steps. In the final step torque bolts, in sequence, to 12 N·m (1.2 kgf·m, 9 lbf·ft).


NOTE:

Wait at least 30 minutes before filling the engine with oil.

Do not run the engine for at least 3 hours after installing the head cover.


24. Ignition Coil

1.

Install the ignition coils.


25. Ignition Coil Cover

1.

Install the ignition coil cover.


26. Cylinder Head Peripheral Assembly

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1.

Install the the EVAP canister purge valve bracket (A).


27. Heater Hose - Reconnection Engine Side

1.

Connect the upper radiator hose (A) and the heater hoses (B).


28. WU-TWC

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1.

Install the WU-TWC cover (A).


2.

Install the WU-TWC (B) with new gaskets (C).


29. A/F Sensor

1.

Install the A/F sensor (A).


2.

Connect the connector.


30. Rocker Arm Oil Control Valve


1.

Install the engine wire harness bracket (A).


2.

Install the rocker arm oil control valve assembly (B) and the rocker arm oil control valve filter (C).


31. Engine Peripheral Hose - Reconnection

1.

Connect the EVAP canister hose (A) and the brake booster vacuum hose (B).


32. Under Cowl Panel

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1.

Install the under cowl panel (A).


33. Center Cowl Cover


1.

If necessary, install the hood rear seal (A).


2.

Connect the windshield washer tube (B).


3.

Install the center cowl cover (C).


34. Both Side Cowl Covers


1.

Install the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


35. Wiper Arm Assembly

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NOTE: Set the wiper arms to the auto-stop position before installation.


1.

Install the wiper arms (A).


2.

Install the cowl top wiper covers (B).


36. Injector Base Assembly

1.

Install the injector base (A) with a new gasket (B).


37. Fuel Injector and Rail Assembly


1.

Install the injectors and fuel rail (A) together.


2.

Connect the quick-connect fitting (B).


38. Ignition Coil Harness - Move


1.

Install the engine harness holder (A).


2.

Connect the connectors.


39. Intake Manifold Assembly

1.

Connect the PCV hose (A).


2.

Install the intake manifold (A) with new gaskets (B).


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3.

Install the intake manifold bracket.


40. Throttle Body - Installation

1.

Install the throttle body (A) with new gasket (B).



2.

Install the harness clamps (A).


3.

Connect the connector (B).


4.

Connect the EVAP canister hose (A) and the brake booster vacuum hose (B).


41. Intake Air Duct

1.

Install the intake air duct.


42. Drive Belt

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1.

Install the drive belt.


43. Air Cleaner Assembly


1.

Install the air cleaner (A).


2.

Install the harness clamp (B).


3.

Connect the intake air pipe (C) and the intake air duct (D).


44. Tubes, Hoses, and Connectors After Installation Check

1.

After installation, check that all tubes, hoses, and connectors are installed correctly.


45. Fuel Filler Cap

1.

Install the fuel fill cap.


46. Battery Terminal - Reconnection


NOTE: If the battery performs abnormally, test the battery.


1.

Clean the battery terminals.


2.

Connect the positive cable (A) to the battery.


NOTE: Always connect the positive side first.


3.

Connect the negative cable and the battery sensor (B) to the battery.


NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal.


4.

Apply multipurpose grease to the terminals to prevent corrosion.


47. HDS DLC - Connection


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


48. Fuel Pump On

1.

From the INSPECTION MENU of the HDS, select Fuel Pump ON.


NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.


2.

Turn the ignition switch to LOCK (0).


49. Fuel Line Leak Check

1.

Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.


50. Radiator Coolant - Replacement

1.

Follow the chart and pour coolant into the radiator up to the base of the filler neck.


NOTE:

Use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (concentrate). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.

Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Honda Extreme Cold Weather Antifreeze/Coolant Type 2 is a 100 % concentration coolant. Do not add water to either coolant.

If the vehicle is regularly driven in very low temperatures (below -22 °F ( -30 °C)), a 60 % concentration of coolant should be used.


Operation

Vehicle Usage (Desired Mixture)

Current Mixture

Coolant Drain

Add Amount of Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (100 % concentrate)

Then add Honda Long Life Antifreeze/Coolant Type 2 (50/50)

Coolant Change

Normal Area (50/50)

50/50
60/40
unknown

Drain radiator, engine block, and reservoir

None

Top off the cooling system

Very Cold Area (60/40)

50/50
unknown

Drain radiator, engine block, and reservoir

About 1.3 L (44 fl oz)

60/40

About 1.2 L (41 fl oz)

Engine Overhaul

Normal Area (50/50)

-

-

None

Very Cold Area (60/40)

-

-

About 1.2 L (41 fl oz)

Coolant Winterizing

Very Cold Area (60/40)

50/50

Drain about 2.0 L (68 fl oz) from radiator

About 1.2 L (41 fl oz)

unknown*

Drain radiator, engine block, and reservoir


*: When you want to winterize the coolant with the minimum amount of coolant change but the current coolant concentration in the vehicle is unknown, you must drain all coolant from the cooling system.


Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))


Except K24Z7 engine

 

Manufacturer

Capacity

At Coolant Change

DENSO

5.59 L (1.477 US gal)

TRAD

5.50 L (1.453 US gal)

After Engine Overhaul (M/T)

DENSO

6.42 L (1.696 US gal)

TRAD

6.33 L (1.672 US gal)

After Engine Overhaul (A/T)

DENSO

6.56 L (1.732 US gal)

TRAD

6.47 L (1.709 US gal)

After Engine Overhaul (CVT)

DENSO

6.52 L (1.722 US gal)

TRAD

6.43 L (1.699 US gal)


Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))


K24Z7 engine

 

Capacity

At Coolant Change

5.5 L (1.45 US gal)

After Engine Overhaul

6.7 L (1.78 US gal)


51. Engine Cover

1.

Install the engine cover.


52. Tire and Wheel-Installation, Front Right

mminmuan

1.

Install the right front wheel.


NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.


53. Splash Shield

1.

Install the splash shield (A).


54. Warm Up The Engine

Start the engine. Hold the engine speed at 3,000 rpm without load (A/T in P or N, M/T in neutral) until the radiator fan comes on, then let it idle.


55. Idle Speed - Inspection

1.

Check the idle speed without electrical load: headlights, blower fan, radiator fan, and air conditioner off.


Idle speed should be:


750±50 rpm (in neutral)


2.

Let the engine idle for 1 minute with high electric load (A/C switch on, temperature set to max cool, blower fan on High, and headlights on high beam).


Idle speed should be:


750±50 rpm (in neutral)


NOTE: If the idle speed is not within specification, do the ECM idle learn procedure. If the idle speed is still not within specification, go to symptom troubleshooting.


56. CKP Pattern Clear/CKP Pattern Learn

1.

Select CRANK PATTERN in the ADJUSTMENT MENU with the HDS.


2.

Select CRANK PATTERN CLEAR, and clear the CKP pattern.


3.

Select CRANK PATTERN LEARNING with the HDS, and follow the screen prompts.


57. Ignition Timing - Inspection


1.

Jump the SCS line with the HDS.


2.

Connect the timing light to the service loop (white tape).



3.

Aim the light toward the pointer (A) on the cam chain case. Check the ignition timing under a no load condition (headlights, blower fan, rear window defogger, and air conditioner are turned off).


Ignition Timing

8±2 ° BTDC (RED mark (B)) at idle


4.

If the ignition timing differs from the specification, check the cam timing. If the cam timing is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the system works properly, and the ECM was substituted, replace the original ECM.


5.

Disconnect the HDS and the timing light.


58. Maintenance Minder Reset

1.

After doing all procedures, select the individual maintenance item you wish to reset with the HDS..


Cylinder Head
...

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