61snc01_06 - engine mechanical - cylinder head

Engine Mechanical

Cylinder Head................................................................

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Special Tools . 6-2Component Location Index . 6-3Engine Compression Inspection . 6-6VTEC Rocker Arm Test . 6-7Valve Clearance Adjustment . 6-10Crankshaft Pulley Removal and Installation . 6-12Cam Chain Removal . 6-14Cam Chain Installation . 6-16Chain Case Oil Seal Installation . 6-20CKP Pulse Plate Replacement . 6-21Cylinder Head Cover Removal . 6-22Cylinder Head Cover Installation . 6-22Cylinder Head Removal . 6-24Camshaft Sprocket Removal . 6-27Camshaft Sprocket Installation . 6-28CMP Pulse Plate Removal and Installation . 6-30Cylinder Head Inspection for Warpage . 6-31Rocker Arm Assembly and Camshaft Removal . 6-32Rocker Arm and Shaft

Disassembly/Reassembly . 6-33Rocker Arm and Shaft Inspection . 6-34Camshaft Inspection . 6-36Valve, Spring, and Valve Seal Removal . 6-38Valve Inspection . 6-39Valve Stem-to-Guide Clearance Inspection . 6-39Valve Guide Replacement . 6-40Valve Seat Reconditioning . 6-42Valve, Spring, and Valve Seal Installation . 6-44Rocker Arm Assembly and Camshaft Installation . 6-45Cylinder Head Installation . 6-45

06/09/19 10:40:47 61SNC010_060_0001

Ref. No. Tool Number Description Qty

6-2

Cylinder Head

Special Tools

07AAJ-PNAA101 Air Pressure Regulator 107HAH-PJ7A100 Valve Guide Reamer, 5.5 mm 107JAA-001020A Socket, 19 mm 107JAB-001020A Holder Handle 107NAB-001040A Holder Attachment, 50 mm 107PAD-0010000 Stem Seal Driver 107757-PJ1010A Valve Spring Compressor Attachment 107742-0010100 Valve Guide Driver, 5.5 mm 107746-0010400 Attachment, 52 x 55 mm 107749-0010000 Driver 107VAJ-P8A010A VTEC Air Adapter 1

06/09/19 10:40:49 61SNC010_060_0002

6-3

Component Location Index

CRANKSHAFT PULLEY

CYLINDER HEAD COVER

HEAD COVER GASKET

CRANKSHAFT PULLEY BOLT

CAMSHAFT SPROCKET

CAM CHAIN GUIDE

CRANKSHAFT POSITION (CKP)PULSE PLATE

CAM CHAIN

CAM CHAINTENSIONER SLIDER

CAM CHAIN TENSIONER

CHAIN CASE

O-RING

CYLINDER HEAD PLUG

CRANKSHAFT POSITION(CKP) SENSOR

(contd)

Removal and Installation, page 6-12

Removal, page 6-22Installation, page 6-22

Removal and Installation, page 6-12


Replacement, page 6-21


06/09/19 10:40:52 61SNC010_060_0003

6-4

Cylinder Head

Component Location Index (contd)

O-RING

CYLINDER HEADGASKET

DOWEL PINS

THERMOSTAT HOUSING

THERMOSTAT

ROCKER ARM OIL CONTROLSOLENOID FILTER

CYLINDER HEAD BOLTS

ROCKER ARM OIL CONTROLSOLENOID

06/09/19 10:40:53 61SNC010_060_0004

6-5

ROCKER ARM ASSEMBLY

VALVE COTTERS

SPRING RETAINER

EXHAUST VALVESPRING

EXHAUST VALVESEAL

O-RING

CYLINDER HEAD

VALVE SPRINGSEAT

INTAKE VALVE

INTAKE VALVE SPRING

INTAKE VALVE SEAL

CAMSHAFT

EXHAUST VALVE

CYLINDER HEAD PLUG

CAMSHAFT POSITION (CMP)PULSE PLATE

EXHAUST VALVEGUIDE

INTAKE VALVE GUIDE

O-RING

LOST MOTION HOLDER

LOST MOTION ASSEMBLY

CAMSHAFT POSITION(CMP) SENSOR

VTEC Rocker Arm Test, page 6-7Rocker Arm Assembly Removal,page 6-32Rocker Arm and Shaft Disassembly/Reassembly, page 6-33Rocker Arm and Shaft Inspection,page 6-34

Removal, page 6-24Inspection, page 6-31Installation, page 6-45


Inspection, page 6-36




Removal, page 6-32Inspection, page 6-45

06/09/19 10:40:57 61SNC010_060_0005

Compression Pressure:Above 980 kPa (10.0 kgf/cm , 142 psi)

Maximum Variation:Within 200 kPa (2.0 kgf/cm , 29 psi)

2

2

6-6

Cylinder Head

Engine Compression Inspection

NOTE: After the inspection, you must reset thepowertrain control module (PCM). Otherwise, the PCMwill continue to stop the fuel injectors from functioning.

1. Warm up the engine to normal operatingtemperature (cooling fan comes on).

2. Turn the ignition switch OFF.

3. Connect the Honda Diagnostic System (HDS) to thedata link connector (DLC) (see step 2 on page 11-3).

4. Turn the ignition switch ON (II).

5. Make sure the HDS communicates with the vehicleand the PCM. If it doesnt communicate,troubleshoot the DLC circuit (see page 11-218).

6. Select PGM-FI, INSPECTION, then AII INJECTORSOFF on the HDS.

7. Turn the ignition switch OFF.

8. Remove the four intake side ignition coils (see page4-19).

9. Remove the four intake side spark plugs.

10. Attach the compression gauge to a spark plug hole.

NOTE: Use a compression gauge with a connectinglength (between the edge and the flange) of lessthan 23 mm (0.9 in.).

11. Remove the No. 61 B IMA 2 (10 A) fuse in theauxiliary under-hood fuse/relay box.

12. Open the throttle fully, then crank the engine withthe starter motor and measure the compression.

13. Measure the compression on the remainingcylinders.

14. If the compression is not within specifications,check the following items, then remeasure thecompression.

Looseness exhaust side spark plug Damaged or worn valves and seats Damaged cylinder head gasket Damaged or worn piston rings Damaged or worn piston and cylinder bore

15. Remove the compression gauge from the sparkplug hole.

16. Install the four intake side spark plugs.

17. Install the four intake side ignition coils (see page4-19).

18. Select PCM reset (see page 11-4) to cancel the ALLINJECTORS OFF function on the HDS.

19. Do the start clutch pressure control calibrationprocedures (see page 14-204).

20. Install the No. 61 B IMA 2 (10 A) fuse in theauxiliary under-hood fuse/relay box.

21. Clear any IMA DTCs that may have been set whiledoing this inspection procedure.

22. If the IMA battery level gauge (BAT) displays nosegment, start the engine, and hold it between3,500 rpm and 4,000 rpm without load (in Park orneutral) until the BAT displays at least threesegments.

06/09/19 10:40:58 61SNC010_060_0006

Special Tools Required

6-7

VTEC Rocker Arm Test

C

A B

A

B

B07AAJ-PNAA101

A07VAJ-P8A010A

Air pressure regulator 07AAJ-PNAA101 VTEC air adapter 07VAJ-P8A010A

1. Start the engine and let it run for 5 minutes, thenturn the ignition switch OFF.

2. Remove the cylinder head cover (see page 6-22).

3. Set the No. 1 piston at top dead center (TDC) (seestep 2 on page 6-10).

4. Push on the intake 1st rocker arm (A) for the No. 1cylinder. Make sure that the intake 1st rocker armand the intake 2nd rocker arm (B) are mechanicallyconnected by the rocker arm pistons and that theintake 2nd rocker arm does not move when pushedmanually. Then move the intake 3rd rocker arm (C)for the No. 1 cylinder. The intake 3rd rocker armshould move independently of the intake 1st rockerarm.

If the intake 2nd rocker arm does not moveindependently and the intake 3rd rocker armmoves independently, go to step 5.

If the intake 2nd rocker arm movesindependently, remove and disassemble therocker arm assembly, and check that the rockerarm pistons between the intake 1st and 2ndrocker arms move smoothly. If any rocker arm orrocker arm piston needs replacing, replace therocker arms for the cylinder as an assembly.

If the intake 3rd rocker arm does not movesindependently, remove and disassemble therocker arm assembly, and check that the rockerarm pistons between the intake 2nd and 3rdrocker arms move smoothly. If any rocker arm orrocker arm piston needs replacing, replace therocker arms for the cylinder as an assembly.

5. Push on the exhaust 1st rocker arm (A) for the No. 1cylinder. Make sure that the exhaust 1st rocker armand the exhaust 2nd rocker arm (B) aremechanically connected by the rocker arm pistonsand that the exhaust 2nd rocker arm does not movewhen pushed manually.

If the exhaust 2nd rocker arm does not moveindependently, go to step 6.

If the exhaust 2nd rocker arm movesindependently, remove and disassemble therocker arm assembly, and check that the rockerarm pistons between the exhaust 1st and 2ndrocker arms move smoothly. If any rocker arm orrocker arm piston needs replacing, replace therocker arms for the cylinder as an assembly.

6. Check that the air pressure on the shop aircompressor gauge indicates over 400 kPa(4.0 kgf/cm , 47 psi).

7. Inspect the valve clearance (see page 6-10).

8. Install the special tool (A) to the cam chain sideinspection hole, then connect the air pressureregulator (B).

(contd)

2

06/09/19 10:40:59 61SNC010_060_0007

Specified Air Pressure:200 kPa (2.0 kgf/cm , 28 psi)2

6-8

Cylinder Head

VTEC Rocker Arm Test (contd)

A

B

B07AAJ-PNAA101

A07VAJ-P8A010A

C

B

A

9. Loosen the valve on the regulator, and apply thespecified air pressure.

10. Push on the intake 1st rocker arm (A) for the No. 1cylinder. Make sure that the intake 1st rocker armand the intake 3rd rocker arm (B) are mechanicallyconnected by the rocker arm pistons and that theintake 3rd rocker arm does not move when pushedmanually.

If the intake 3rd rocker arm does not moveindependently, go to step 11.

If the intake 3rd rocker arm moves independently,remove and disassemble the rocker armassembly, and check that the rocker arm pistonsbetween the intake 1st and 3rd rocker arms movesmoothly. If any rocker arm or rocker arm pistonneeds replacing, replace the rocker arms for thecylinder as an assembly.

11. Tighten the valve on the regulator, then remove thespecial tools.

12. Install the special tool (A) to the transmission sideinspection hole, then connect the air pressureregulator (B).

13. Move the intake 2nd rocker arm (A) and intake 3rdrocker arm (B) for the No. 1 cylinder. The intake 2ndand intake 3rd rocker arm should moveindependently of the intake 1st rocker arm (C).

If the intake 2nd and 3rd rocker arms moveindependently, go to step 14.

If the intake 2nd or intake 3rd rocker arm doesnot move independently, remove anddisassemble the rocker arm assembly, and checkthat the rocker arm pistons between the intake1st and 2nd rocker arms move or intake 1st and3rd smoothly. If any rocker arm or rocker armpiston needs replacing, replace the rocker armsfor the cylinder as an assembly.

06/09/19 10:41:00 61SNC010_060_0008

6-9

A

B

14. Move the exhaust 2nd rocker arm (A) for the No. 1cylinder. The exhaust 2nd rocker arm should moveindependently of the exhaust 1st rocker arm (B).

If the exhaust 2nd rocker arm movesindependently, go to step 15.

If the exhaust 2nd rocker arm does not moveindependently, remove and disassemble therocker arm assembly, and check that the rockerarm pistons between the exhaust 1st and 2ndrocker arms move smoothly. If any rocker arm orrocker arm piston needs replacing, replace therocker arms for the cylinder as an assembly.

15. Tighten the valve on the regulator, then remove thespecial tools.

16. Repeat step 4 to 15 on the remaining cylindersrocker arms with each piston at TDC. When all therocker arms pass the test, go to step 17.

17. Install the cylinder head cover (see page 6-22).

06/09/19 10:41:00 61SNC010_060_0009

Valve ClearanceIntake: 0.15 0.19 mm (0.006 0.007 in.)Exhaust: 0.24 0.28 mm (0.009 0.011 in.)

Specified Torque20 Nm (2.0 kgfm, 14 lbfft)Apply new engine oil to the nut threads.

6-10

Cylinder Head

Valve Clearance Adjustment

A

B

EXHAUST

INTAKE

No. 1 No. 2 No. 3 No. 4

No. 1 No. 2 No. 3 No. 4

A

A

B20 Nm(2.0 kgfm,15 lbfft)

NOTE: Adjust the valves only when the cylinder headtemperature is less than 100 F (38 C).


2. Set the No. 1 piston at top dead center (TDC). TheUP mark (A) on the camshaft sprocket should beat the top, and the TDC grooves (B) on the camshaftsprocket should line up with the top edge of thechain case.

3. Select the correct thickness feeler gauge for thevalves youre going to check.

4. Insert the feeler gauge (A) between the adjustingscrew and the end of the valve stem on No. 1cylinder and slide it back and forth; you should feela slight amount of drag.

5. If you feel too much or too little drag, loosen thelocknut (A), and turn the adjusting screw (B) untilthe drag on the feeler gauge is correct.

6. Tighten the locknut and recheck the clearance.Repeat the adjustment if necessary.

06/09/19 10:41:02 61SNC010_060_0010

6-11

A

A

A

7. Rotate the crankshaft clockwise. Align the No. 3piston TDC groove (A) on the camshaft sprocketwith the top edge of the chain case.

8. Check the valve clearance on the No. 3 cylinder;adjust it if necessary

9. Rotate the crankshaft clockwise. Align the No. 4piston TDC groove (A) on the camshaft sprocketwith the top edge of the chain.

10. Check the valve clearance on the No. 4 cylinder;adjust it if necessary.

11. Rotate the crankshaft clockwise. Align the No. 2piston TDC groove (A) on the camshaft sprocketwith the top edge of the head.

12. Check the valve clearance on the No. 2 cylinder;adjust it if necessary.


06/09/19 10:41:03 61SNC010_060_0011


: Clean: Lubricate with new engine oil

Removal

Installation

6-12

Cylinder Head

Crankshaft Pulley Removal and Installation

B07NAB-001040A

A07JAB-001020A

C07JAA-001020A(or commerciallyavailable)

B

AC

D

Holder handle 07JAB-001020A Holder attachment, 50 mm 07NAB-001040A Socket, 19 mm 07JAA-001020Aor a commercially available 19 mm socket

1. Remove the front wheels.

2. Remove the splash shield and the engineundercover (see step 22 on page 5-5).

3. Remove the drive belt (see page 10-10).

4. Hold the pulley with the holder handle (A) and theholder attachment (B).

5. Remove the crankshaft pulley bolt with a 19 mmsocket (C) and a breaker bar.

6. Remove the under-floor three way catalyticconverter (TWC) (see step 40 on page 5-8).

7. Support the engine with a jack and a wood blockunder the oil pan.

8. Remove the lower torque rod mounting bolts (seestep 49 on page 5-9).

9. Remove the crankshaft pulley while moving theengine forward.

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

2. Install the crankshaft pulley while moving theengine forward and loosely install the crankshaftpulley.

3. Install the lower torque rod mounting bolts (seestep 15 on page 5-15).

4. Remove the jack and the wood block.

5. Install the under-floor TWC (see step 26 on page5-16).

06/09/19 10:41:03 61SNC010_060_0012

6-13

B07NAB-001040A

A07JAB-001020A

C07JAA-001020A(or commerciallyavailable)

90

D

E

6. Tighten the crankshaft pulley bolt. Do not use animpact wrench.

1 Hold the pulley with the holder handle (A) andpulley holder attachment (B), then tighten thebolt to 37 Nm (3.8 kgfm, 27 lbfft) with atorque wrench and a heavy duty 19 mm socket(C). If the pulley bolt or crankshaft are new,tighten the bolt to 177 Nm (18.0 kgfm,130 lbfft), then remove the bolt and tighten itto 37 Nm (3.8 kgfm, 27 lbfft).

2 Mark the bolt head (D) and the crankshaftpulley (E) as shown, then tighten the bolt anadditional 90 (The mark on the bolt head linesup with the mark on the crankshaft pulley).

7. Install the drive belt (see page 10-10).

8. Install the splash shield and the engine undercover(see step 42 on page 5-19).

9. Install the front wheels.

06/09/19 10:41:04 61SNC010_060_0013

6-14

Cylinder Head

Cam Chain Removal

A

B

A

B

C

B

C

A

NOTE: Keep the cam chain away from magnetic fields.




4. Turn the crankshaft pulley so its top dead center(TDC) mark (A) lines up with the pointer (B).

5. Remove the water pump pulley (see step 4 on page10-5).


7. Remove the crankshaft pulley (see page 6-12).

8. Remove the oil pan (see page 7-11).

9. Support the engine with a jack and a wood blockunder the engine block.

10. Remove the ground cable (A), then remove the sideengine mount bracket (B).

11. Disconnect the crankshaft position (CKP) sensorconnector (A), then remove the dipstick tubemounting bolt (B) and the harness clamps (C).

06/09/19 10:41:05 61SNC010_060_0014

Standard Distance: 19 mm (0.75 in.)Service Limit: 15 mm (0.59 in.)

6-15

A

B

A

B C

12. Remove the chain case (A), then remove thecrankshaft position (CKP) pulse plate (B).

13. Measure the cam chain separation. If the distanceis less than the service limit, replace the cam chainand the cam chain tensioner.

14. Apply new engine oil to the sliding surface of thecam chain tensioner slider (A).

15. Hold the cam chain tensioner slider with ascrewdriver, then remove the bolt (B), and loosenthe bolt (C).

16. Remove the cam chain tensioner slider.

(contd)

06/09/19 10:41:06 61SNC010_060_0015

6-166-16

Cylinder Head

Cam Chain Removal (contd) Cam Chain Installation

A

B

B A

A

B

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

18. Remove the cam chain.


1. Set the crankshaft to top dead center (TDC). Alignthe TDC mark (A) on the crankshaft sprocket withthe pointer (B) on the oil pump.

2. Set the No. 1 piston at TDC. The UP mark (A) onthe camshaft sprocket should be at the top, and theTDC grooves (B) on the camshaft sprocket shouldline up with the top edge of the cylinder head.

06/09/19 10:41:07 61SNC010_060_0016

6-17

B

A

AB

CB

A8 x 1.25 mm22 Nm(2.2 kgfm, 16 lbfft)

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

3. Install the cam chain on the crankshaft sprocketwith the colored piece (A) aligned with the TDCmark (B) on the crankshaft sprocket.

4. Install the cam chain on the camshaft sprocket withthe pointer (A) aligned with the center of the twocolored pieces (B).

5. Apply new engine oil to the threads of the camchain tensioner mounting bolt (A).

6. Install the cam chain tensioner (B) and the camchain guide (C).

7. Install the cam chain tensioner slider, and tightenthe lower side bolt loosely.

(contd)

06/09/19 10:41:08 61SNC010_060_0017

6-18

Cylinder Head

Cam Chain Installation (contd)

A

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

B

A

8. Apply new engine oil to the sliding surface of thecam chain tensioner slider (A).

9. Turn the cam chain tensioner clockwise tocompress the cam chain tensioner slider. Install theremaining bolt, then tighten the two bolts.

10. Check the chain case oil seal for damage. If the oilseal is damaged, replace the chain case oil seal(see page 6-20).

11. Remove any old liquid gasket from the chain casemating surfaces, bolts, and bolt holes.

12. Clean and dry the chain case mating surfaces.

13. Apply liquid gasket, P/N 08717-0004, 08718-0001,08718-0003, or 08718-0009, evenly to the cylinderhead and engine block mating surface of the chaincase. Install the component within 5 minutes ofapplying the liquid gasket.

NOTE: Apply a 1.5 mm wide bead of liquid gasket along

the broken lines (A). Apply a 3.0 mm wide bead of liquid gasket to the

engine block upper surface contact areas (B) onthe chain case.

If you apply liquid gasket P/N 08718-0012, thecomponent must be installed with 4 minutes.

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

06/09/19 10:41:09 61SNC010_060_0018

6-19

A

B

8 x 1.25 mm31 Nm(3.2 kgfm, 23 lbfft)

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

C

A

A

B6 x 1.0 mm9.8 Nm(1.0 kgfm,7.2 lbfft)

B

A

12 x 1.25 mm72 Nm(7.3 kgfm,53 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm, 40 lbfft)

12 x 1.25 mm54 Nm(5.5 kgfm,40 lbfft)

6 x 1.0 mm9.8 Nm (1.0 kgfm, 7.2 lbfft)

14. Install the crankshaft position (CKP) pulse plate (A)and the chain case (B).

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 chain case.

15. Install the harness clamps (A) and the dipstick tubemounting bolt (B), then connect the CKP sensorconnector (C).

16. Install the side engine mount bracket (A), thentighten the mounting bolts and nut in thenumbered sequence shown.

17. Install the ground cable (B).


19. Install the oil pan (see page 7-27).

20. Install the crankshaft pulley (see page 6-12).


22. Install the water pump pulley (see page 10-5).




26. Do the crankshaft position (CKP) pattern clear/CKPpattern learn procedure (see page 11-4).

Replace.

Replace.

06/09/19 10:41:11 61SNC010_060_0019


Oil Seal Installed Height:34.5 35.2 mm (1.36 1.39 in.)

6-20

Cylinder Head

Chain Case Oil Seal Installation

07749-0010000

07746-0010400

34.5 35.2 mm(1.36 1.39 in.)

Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400

1. Use the special tools to drive a new oil sealsquarely into the chain case to the specifiedinstalled height.

2. Measure the distance between the chain casesurface and the oil seal.

06/09/19 10:41:11 61SNC010_060_0020

6-21

CKP Pulse Plate Replacement

A




4. Turn the crankshaft pulley so its top dead center(TDC) mark lines up with the pointer (see step 2 onpage 6-10).

5. Remove the water pump pulley (see step 4 on page10-5).



8. Remove the oil pan (see page 7-11).

9. Support the engine with a jack and a wood blockunder the engine block.

10. Remove the ground cable, then remove the sideengine mount bracket (see step 59 on page 5-11).

11. Disconnect the crankshaft position (CKP) sensorconnector, then remove the harness clamp and thedipstick tube mounting bolt (see step 11 on page6-14).

12. Remove the chain case (see step 12 on page 6-15).

13. Remove the CKP pulse plate (A).

14. Install the CKP pulse plate.


16. Remove all of the old liquid gasket from the chaincase mating surfaces, bolt, and bolt holes.


18. Apply liquid gasket, P/N 08717-0004, 08718-0001,08718-0003 or 08718-0009, evenly to the engineblock mating surface of the chain case. Install thecomponent within 5 minutes of applying the liquidgasket (see step 13 on page 6-18).

NOTE: If you apply liquid gasket P/N 08718-0012, the

component must be installed with 4 minutes. If too much time has passed after applying the

liquid gasket, remove the old liquid gasket andresidue, then reapply new liquid gasket.

19. Install the chain case (see step 14 on page 6-19).

20. Install the side engine mount bracket, then installthe ground cable (see step 16 on page 6-19).


22. Install the oil pan (see page 7-27).



25. Install the water pump pulley (see step 4 on page10-5).

26. Install the drive belt. (see page 10-10).



29. Do the crankshaft (CKP) pattern clear/CKP patternlearn procedure (see page 11-4).

06/09/19 10:41:58 61SNC010_060_0021

6-226-22

Cylinder Head

Cylinder Head Cover Removal Cylinder Head Cover Installation

A

B

B

A

C

A

1. Remove the engine cover (see step 7 on page 5-3).

2. Remove the eight ignition coils (see page 4-19).

3. Remove the harness holder (A) and the breatherhose (B).

4. Remove the cylinder head cover.

1. Check the spark plug seals (A) for damage. If theseal is damaged, replace the spark plug seals.

2. Thoroughly clean the head cover gasket and thegroove.

3. Install the head cover gasket (B) in the groove ofthe cylinder head cover (C).

4. Check that the mating surfaces are clean and dry.

5. Apply a 3.0 mm wide bead of the liquid gasket, P/N08717-0004, 08718-0001, 08718-0003, or 08718-0009, on the chain case mating areas (A). Install thecomponent within 5 minutes of applying the liquidgasket.

NOTE: If you apply liquid gasket P/N 08718-0012, the



06/09/19 10:41:59 61SNC010_060_0022

6-23

B

A

A

B

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

6 x 1.0 mm9.8 Nm(1.0 kgfm,7.2 lbfft)

6. Once the cylinder head cover (A) is on the cylinderhead, slide the cover slightly back and forth to seatthe head cover gasket.

7. Inspect the cover washer (B). Replace any washerthat is damaged or deteriorated.

8. Tighten the bolts in two or three steps. In the finalstep, tighten all bolts in sequence shown to 12 Nm(1.2 kgfm, 8.7 lbfft).

9. Install the breather hose (A) and the harness holder(B).

10. Install the eight ignition coils (see page 4-19).

11. Install the engine cover (see step 55 on page 5-21).

12. After assembly, wait at least 30 minutes beforefilling the engine with oil.

06/09/19 10:42:00 61SNC010_060_0023

6-24

Cylinder Head

Cylinder Head Removal

A

B

C

C A

B

E

B

C

A

D

C

B

D

A

NOTE: Use fender covers to avoid damaging painted

surfaces. To avoid damaging the wire and terminals, unplug

the wiring connectors carefully while holding theconnector portion.

To avoid damaging the cylinder head, wait until theengine coolant temperature drops below 100 F(38 C) before loosening the cylinder head bolts.

Mark all wiring and hoses to avoid misconnection.Also, be sure that they do not contact other wiring orhoses, or interfere with other parts.

Keep the cam chain away from magnetic fields.

1. Relieve the fuel pressure (see page 11-356).

2. Remove the engine cover (see step 7 on page 5-3).

3. Drain the engine coolant (see page 10-6).

4. Remove the air cleaner assembly (see page 11-381).

5. Remove the intake manifold (see page 9-3).

6. Disconnect the knock sensor connector (A), thenremove the harness clamp (B) and the connectingpipe (C).

7. Disconnect the camshaft position (CMP) sensor (A)and the engine coolant temperature (ECT) sensor 1connector (B), then remove the harness clamp (C).

8. Remove the eight ignition coils (see page 4-19).

9. Remove the harness holder and the breather hose(see step 3 on page 6-22).

10. Disconnect the purge control solenoid valveconnector (A), then remove the clip (B).

11. Disconnect the purge joint from the clamp stay (C),then remove the fuel pipe nut (D) and remove thepurge control solenoid stay bolts (E).

12. Remove the upper radiator hose (A), lower radiatorhose (B), water bypass hose (C), and heater hoses(D).

06/09/20 16:08:14 61SNC010_060_0024

6-25

C

B

A

A


14. Turn the crankshaft pulley so its top dead center(TDC) mark lines up with the pointer (see step 4 onpage 6-14).

15. Remove the water pump (see page 10-5).


17. Remove the under floor three way catalyticconverter (TWC) and the warm-up three waycatalytic converter (WU-TWC) (see step 40 on page5-8).


19. Support the engine with a jack and a wood blockunder the oil pan.

20. Remove the ground cable, then remove the sideengine mount bracket (see step 10 on page 6-14).

21. Disconnect the crankshaft position (CKP) sensor (A)and the harness clamp (B), then remove thedipstick tube (C).

22. Remove the chain case.

23. Make a reference mark (A) across the camshaftsprocket and the cam chain.

24. Loosely install the crankshaft pulley.

25. Apply new engine oil to the sliding surface of thecam chain tensioner through the oil return hole inthe cylinder head.

(contd)

06/09/19 10:42:03 61SNC010_060_0025

6-26

Cylinder Head

Cylinder Head Removal (contd)

A

C

D

B

26. Hold the crankshaft pulley and set the socketwrench (A) on the camshaft sprocket bolt.

27. Turn the camshaft clockwise to compress the camchain tensioner, then install the 6 x 1.0 mm bolt (B)in the bolt hole (C) in the engine block through thecam chain tensioner (D).

NOTE: Turning torque should not exceed 44 Nm

(4.5 kgfm, 33 lbfft) when turning the camshaft. Do not turn the camshaft counterclockwise.

28. Hold the camshaft with a 27 mm open-end wrench,then remove the camshaft sprocket.

29. Remove the top bolt that secures the cam chainguide.

30. Remove the cylinder head bolts. To preventwarpage, loosen the bolts in sequence 1/3 turn at atime; repeat the sequence until all bolts areloosened.

31. Remove the cylinder head.

06/09/19 10:42:05 61SNC010_060_0026

6-27

Camshaft Sprocket Removal

A

A

C

D

B

E



2. Make a reference mark (A) across the camshaftsprocket and the cam chain.


4. Remove the cylinder head plug.


6. Remove the maintenance bolt (B), and turn thecamshaft clockwise to compress the cam chaintensioner, then install the 6 x 1.0 mm bolt (C) in thebolt hole (D) in the engine block through themaintenance hole and the cam chain tensioner (E).



(contd)

06/09/19 10:42:06 61SNC010_060_0027

Specified Torque: 56 Nm (5.7 kgfm, 41 lbfft)

6-286-28

Cylinder Head

Camshaft Sprocket Removal(contd)

Camshaft Sprocket Installation

A

7. Hold the camshaft with a 27 mm open-end wrench,then loosen the camshaft sprocket bolt.

8. Remove the camshaft sprocket bolt, then removethe camshaft sprocket.

NOTE: Hang the cam chain with a wire.


1. Install the cam chain around the camshaft sprocketaligned with the reference mark (A), then install thecamshaft sprocket on the camshaft.

2. Hold the camshaft with a 27 mm open-end wrench,then tighten the bolt.

NOTE: Apply new engine oil to the bolt threads andflange.

06/09/19 10:42:07 61SNC010_060_0028

6-29

A

B

D

C14 x 1.25 mm20 Nm (2.0 kgfm, 15 lbfft)



5. Turn the camshaft clockwise to compress the camchain tensioner, then remove the 6 x 1.0 mm bolt(B).



6. Install the maintenance bolt (C) with a new washer(D).

7. Install the new cylinder head plug.


06/09/19 10:42:08 61SNC010_060_0029

Removal

6-30

Cylinder Head

CMP Pulse Plate Removal and Installation

1. Remove the air cleaner assembly (see page 11-381).


3. Remove the purge control solenoid valve stay (seestep 16 on page 5-5).

4. Remove the cylinder head plug.

5. Hold the camshaft with a 27 mm open-end wrench,then loosen the bolt.

6. Remove the camshaft position (CMP) pulse plate.

06/09/19 10:42:09 61SNC010_060_0030

Installation

WarpageStandard (New): 0.07 mm (0.0028 in.)Service Limit: 0.08 mm (0.0031 in.)

Cylinder Head HeightStandard (New): 119.9 120.1 mm

(4.720 4.728 in.)

6-316-31

Cylinder Head Inspection forWarpage

B

A

C14 x 1.5 mm34 Nm (3.5 kgfm, 25 lbfft)

PRECISION STRAIGHT EDGE

1. Install the CMP pulse plate (A). Hold the camshaftwith an open-end wrench (B), then tighten the bolt(C).

2. Install the new cylinder head plug.

3. Install the purge control solenoid valve stay (seestep 45 on page 5-19).


5. Install the air cleaner assembly (see page 11-381).

1. Remove the cylinder head (see page 6-24).

2. Inspect the camshaft (see page 6-36).

3. Check the cylinder head for warpage. Measurealong the edges, and three ways across the center.

If warpage is less than 0.08 mm (0.0031 in.)cylinder head resurfacing is not required.

If warpage is between 0.08 mm (0.0031 in.) and0.2 mm (0.008 in.), resurface the cylinder head.

Maximum resurface limit is 0.2 mm (0.008 in.)based on a height of 120 mm (4.72 in.).

06/09/19 10:42:10 61SNC010_060_0031

6-32

Cylinder Head

Rocker Arm Assembly and Camshaft Removal

A

A

A

B

C

D

1. Remove the camshaft sprocket (see page 6-27).

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

3. Remove the lost motion holder bolts and thecamshaft holder bolts. To prevent damaging thecamshaft, loosen the bolts two turns at a time, in acrisscross pattern.

4. Remove the lost motion holder (A), the lost motionassembly (B), and the rocker arm assembly (C),then remove the camshaft (D).

06/09/19 10:42:12 61SNC010_060_0032

6-33

Rocker Arm and Shaft Disassembly/Reassembly

ROCKER SHAFT

NO. 1CAMSHAFTHOLDER

LOST MOTIONASSEMBLY

ROCKER SHAFT BOLT8 x 1.25 mm20 Nm (2.0 kgfm, 15 lbfft)

ROCKER SHAFT BOLT8 x 1.25 mm20 Nm (2.0 kgfm, 15 lbfft)

LOST MOTIONASSEMBLY

LOST MOTION HOLDER BOLT8 x 1.25 mm22 Nm (2.2 kgfm, 16 lbfft)

LOST MOTION HOLDER

EXHAUST1st and 2ndROCKER ARMASSEMBLY

INTAKE1st, 2nd and 3rdROCKER ARMASSEMBLY

NO. 2CAMSHAFTHOLDER

NO.3CAMSHAFTHOLDER

NO.4CAMSHAFTHOLDER

NO.5CAMSHAFTHOLDER

NOTE: Identify parts as they are removed so they can be reinstalled in their original location. Remove the rocker shaft bolts before disassembling the rocker arms. Inspect the rocker shaft and rocker arms (see page 6-34). If reused, the rocker arms must be installed in their original location. Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to any contact points. Apply new engine oil to the threads of the rocker shaft bolts when installing them. When replacing the rocker arm assembly, remove the fastening hardware from the new rocker arm assembly.

06/09/19 10:42:13 61SNC010_060_0033

Rocker Arm-to-Shaft ClearanceStandard (New): 0.017 0.045 mm

(0.0003 0.0018 in.)Service Limit: 0.067 mm (0.0026 in.)

6-34

Cylinder Head

Rocker Arm and Shaft Inspection

A

1. Remove the rocker arm assembly (see page 6-32).

2. Disassemble the rocker arm assembly (see page6-33).

3. Measure the diameter of the shaft at the first rockerlocation.

4. Zero the gauge (A) to the shaft diameter.

5. Measure the inside diameter of the rocker arm, andcheck it for an out-of-round condition.

6. Repeat for all the rockers and both shafts. If theclearance is over the limit, replace the rocker shaftand all over-tolerance rocker arms. If any intakerocker arm needs replacement, replace all fiverocker arms in that set (intake 1st, 2nd, 3rd, exhaust1st and 2nd).

06/09/19 10:42:13 61SNC010_060_0034

Rocker Arms

6-35

A B

B

A

A

7. Inspect the rocker arm synchronizing pistons (A).Push them manually. If they do not move smoothly,replace the rocker arm set.

NOTE: Apply new engine oil to the pistons when

reassembling. When reassembling the intake 1st and exhaust

1st rocker arms (B), carefully apply air pressureto the oil passage of the rocker arm.

8. Reassemble the rocker arm assembly (see page6-33).

9. Install the rocker arm assembly (see page 6-45).

06/09/19 10:42:14 61SNC010_060_0035

Specified Torque8 mm Bolts:22 Nm (2.2 kgfm, 16 lbfft)Apply new engine oil to the bolt threads and flange.6 mm Bolt:12 Nm (1.2 kgfm, 8.7 lbfft)Apply new engine oil to the bolt threads and flange.

Camshaft End PlayStandard (New): 0.05 0.15 mm (0.002 0.006 in.)Service Limit: 0.3 mm (0.01 in.)

6-36

Cylinder Head

Camshaft Inspection

NOTE: Do not rotate the camshaft during inspection.

1. Remove the rocker arm assembly (see page 6-32).

2. Put the camshaft, the camshaft holders, and thelost motion holder on the cylinder head, thentighten the bolts to the specified torque.

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

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

06/09/19 10:42:14 61SNC010_060_0036

Camshaft-to-Holder Oil ClearanceStandard (New): 0.050 0.089 mm


Camshaft Total RunoutStandard (New): 0.03 mm (0.001 in.) max.Service Limit: 0.04 mm (0.002 in.)

Cam Lobe Height Standard (New):

6-37

2nd 3rd 2nd

EXHAUST INTAKE

C/C

1st1st

5. Loosen the lost motion holder bolts and thecamshaft holder bolts two turns at a time, in acrisscross pattern. Then remove the lost motionholder and the camshaft holders from the cylinderhead.

6. Lift the camshaft out of the cylinder head, wipe itclean, then inspect the lift ramps. Replace thecamshaft if any lobes are pitted, scored, orexcessively worn.

7. Clean the camshaft journal surfaces in the cylinderhead, then set the camshaft back in place. Place aplastigage strip across each journal.

8. Install the camshaft holders, then tighten the boltsto the specified torque as shown in step 2.

9. Remove the camshaft holders. Measure the widestpart of plastigage on each journal.

If the camshaft-to-holder clearance is withinlimits, go to step 11.

If the camshaft-to-holder clearance is beyond theservice limit and the camshaft has been replaced,replace the cylinder head.

If the camshaft-to-holder clearance is beyond theservice limit and the camshaft has not beenreplaced, go to step 10.

10. Check the total runout with the camshaft supportedon V-blocks.

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

If the total runout is beyond the service limit,replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is stillbeyond the service limit, replace the cylinderhead.

11. Measure cam lobe height.

INTAKE EXHAUST2nd 35.568 mm

(1.4003 in.)35.699 mm(1.4054 in.)

3rd 36.060 mm(1.4196 in.)

1st 29.700 mm(1.1692 in.)

29.900 mm(1.1771 in.)

06/09/19 10:42:15 61SNC010_060_0037


6-38

Cylinder Head

Valve, Spring, and Valve Seal Removal

B

A

07757-PJ1010A

Valve spring compressor attachment 07757-PJ1010A

Identify the valves and valve springs as they areremoved so that each item can be reinstalled in itsoriginal position.

1. Remove the cylinder head (see page 6-24).

2. Remove the rocker arm assembly and the camshaft(see page 6-32).

3. Using an appropriate-sized socket (A) and a plasticmallet (B), lightly tap the valve retainer to loosenthe valve cotters.

4. Install the valve spring compressor attachment andthe valve spring compressor. Compress the springand remove the valve cotters.

5. Remove the valve spring compressor, the valvespring compressor attachment, the spring retainer,and the spring.

6. Install the valve guide seal remover.

7. Remove the valve seal.

8. Remove the valve spring seat and the valve.

06/09/19 10:42:17 61SNC010_060_0038

Intake Valve DimensionsA Standard (New): 34.85 35.15 mm

(1.372 1.383 in.)B Standard (New): 117.65 118.15 mm

(4.632 4.652 in.)C Standard (New): 5.48 5.49 mm

(0.2157 0.2161 in.)C Service Limit: 5.45 mm (0.215 in.)

Exhaust Valve DimensionsA Standard (New): 29.85 30.15 mm

(1.175 1.187 in.)B Standard (New): 117.75 118.25 mm

(4.635 4.659 in.)C Standard (New): 5.45 5.46 mm

(0.2146 0.2150 in.)C Service Limit: 5.42 mm (0.213 in.)

Intake Valve Stem-to-Guide ClearanceStandard (New): 0.04 0.10 mm


Exhaust Valve Stem-to-Guide ClearanceStandard (New): 0.10 0.16 mm


Intake Valve Stem-to-Guide ClearanceStandard (New): 0.020 0.050 mm


Exhaust Valve Stem-to-Guide ClearanceStandard (New): 0.050 0.080 mm


6-396-39

Valve Inspection Valve Stem-to-Guide ClearanceInspection

C

B

A

1. Remove the valves (see page 6-38).

2. Measure the valve in these areas. 1. Remove the valves (see page 6-38).

2. Slide the valve out of its guide about 10 mm(0.39 in.), then measure the guide-to-stemclearance with a dial indicator while rocking thestem in the direction of normal thrust (wobblemethod).

If the measurement exceeds the service limit,recheck it using a new valve.

If the measurement is now within the servicelimit, reassemble using a new valve.

If the measurement with a new valve stillexceeds the service limit, go to step 3.

3. Subtract the O.D. of the valve stem, measured witha micrometer, from the I.D. of the valve guide,measured with an inside micrometer or ball gauge.Take the measurements in three places along thevalve stem and three places inside the valve guide.The difference between the largest guidemeasurement and the smallest stem measurementshould not exceed the service limit.

06/09/19 10:42:17 61SNC010_060_0039


6-40

Cylinder Head

Valve Guide Replacement

A 5.3 mm(0.21 in.)

10.8 mm(0.42 in.)

87 mm(3.43 in.)

57 mm(2.24 in.)

07742-0010100

Valve guide driver, 5.5 mm 07742-0010100 Valve guide reamer, 5.5 mm 07HAH-PJ7A100

1. Inspect valve stem-to-guide clearance (see page6-39).

2. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit thediameter of the valve guides. In most cases, thesame procedure can be done using the special tooland a conventional hammer.

3. Select the proper replacement guides, and chillthem in the freezer section of a refrigerator forabout an hour.

4. Use a hot plate or oven to evenly heat the cylinderhead to 300 F (150 C). Monitor the temperaturewith a cooking thermometer. Do not get the headhotter than 300 F (150 C); excessive heat mayloosen the valve seats.

5. Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm(0.1 in.) towards the combustion chamber. This willknock off some of the carbon and make removaleasier. Hold the air hammer directly in line with thevalve guide to prevent damaging the driver. Wearsafety goggles or a face shield.

6. Turn the head over, and drive the guide out towardthe camshaft side of the head.

7. If a valve guide wont move, drill it out with a 8 mm(5/16 in.) bit, then try again.

NOTE: Drill guides only in extreme cases; youcould damage the cylinder head if the guide breaks.

8. Take out the new guide(s) from the freezer, one at atime, as you need them.

06/09/19 10:42:19 61SNC010_060_0040

Valve Guide Installed Height:16.25 16.75 mm (0.640 0.659 in.)

6-41

07742-0010100

A

B

07HAH-PJ7A100

9. Apply a thin coat of new engine oil to the outside ofthe new valve guide. Install the guide from thecamshaft side of the head; use the valve guidedriver to drive the guide into the specified installedheight (A) of the guide (B). If you have all eightguides to do, you may have to reheat the head.

10. Coat both the reamer and the valve guide withcutting oil.

11. Rotate the reamer clockwise the full length of thevalve guide bore.

12. Continue to rotate the reamer clockwise whiledrawing it from the bore.

13. Thoroughly wash the guide in detergent and waterto remove any cutting residue.

14. Check the clearances with a valve (see page 6-39).Verify that a valve slides in the intake and exhaustvalve guides without being stuck.

15. Inspect the valve seating, if necessary renew thevalve seat using a valve seat cutter (see page 6-42).

06/09/19 10:42:42 61SNC010_060_0041

Valve Seat WidthIntake:Standard (New): 0.850 1.150 mm

(0.0335 0.0453 in.)Service Limit: 1.60 mm (0.063 in.)Exhaust:Standard (New): 1.250 1.550 mm


6-42

Cylinder Head

Valve Seat Reconditioning

30

45

60

B

A

1. Inspect valve stem-to-guide clearance (see page6-39). If the valve guides are worn, replace them(see page 6-40) before cutting the valve seats.

2. Renew the valve seats in the cylinder head using avalve seat cutter.

3. Carefully cut a 45 seat, removing only enoughmaterial to ensure a smooth and concentric seat.

4. Bevel the upper edge of the seat with the 30 cutterand the lower edge of the seat with the 60 cutter.Check the width of the seat and adjust accordingly.

5. Make one more very light pass with the 45 cutterto remove any possible burrs caused by the othercutters.

6. After resurfacing the seat, inspect for even valveseating: Apply Prussian Blue compound (A) to thevalve face. Insert the valve in its original location inthe head, then lift it and snap it closed against theseat several times.

7. The actual valve seating surface (B), as shown bythe blue compound, should be centered on the seat.

If it is too high (closer to the valve stem), youmust make a second cut with the 60 cutter tomove 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 mustmake a second cut with the 30 cutter to move itup, then make one more cut with the 45 cutterto restore seat width.

NOTE: The final cut should always be made withthe 45 cutter.

06/09/19 10:42:43 61SNC010_060_0042

Intake Valve Stem Installed HeightStandard (New): 47.7 48.1 mm


Exhaust Valve Stem Installed HeightStandard (New): 47.6 48.0 mm


6-43

A

8. Insert the intake and exhaust valves in the head,and measure the valve stem installed height (A).

9. If the valve stem installed height is over the servicelimit, replace the valve and recheck. If it is still overthe service limit, replace the cylinder head; thevalve seat in the head is too deep.

06/09/19 10:42:43 61SNC010_060_0043


6-44

Cylinder Head

Valve, Spring, and Valve Seal Installation

B07PAD-0010000

A

F D

E C

07757-PJ1010A

A

Stem seal driver 07PAD-0010000 Valve spring compressor attachment 07757-PJ1010A

1. Coat the valve stems with new engine oil. Installthe valves in the valve guides.

2. Check that the valves move up and down smoothly.

3. Install the spring seats on the cylinder head.

4. Install the new valve seals (A) using the stem sealdriver (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.

5. Install the valve spring. Place the end of the valvespring with closely wound coils toward the cylinderhead.

6. Install the spring retainer.

7. Install the valve spring compressor attachment andthe valve spring compressor. Compress the springand install the valve cotters.

8. Remove the valve spring compressor and the valvespring compressor attachment.

9. Lightly tap the end of each valve stem two or threetimes with a plastic mallet (A) to ensure properseating of the valve and the valve cotters. Tap thevalve stem only along its axis so you do not bendthe stem.

NOTE: Use 5.5 mm side.

06/09/19 10:42:44 61SNC010_060_0044

Specified Torque8 mm Bolts: 22 Nm (2.2 kgfm, 16 lbfft)6 mm Bolt: 12 Nm (1.2 kgfm, 8.7 lbfft)6 mm Bolt:

6-456-45

Rocker Arm Assembly andCamshaft Installation

Cylinder Head Installation

D

C

B

A

A

B

B 50 mm (2.0 in.)

A 45 mm (1.8 in.)

1. Reassemble the rocker arm assembly (see page6-33).

2. Apply new engine oil to the camshaft lobes andjournals.

3. Install the camshaft (A) rocker arm assembly (B),then install the lost motion assembly (C) and thelost motion holder (D).

4. Apply new engine oil to the bolt threads and flange.Tighten each bolt two turns at a time in sequence.

5. Install the camshaft sprocket (see page 6-28).

6. Adjust the valve clearance (see page 6-10).

Install the cylinder head in the reverse order ofremoval:

1. Clean the cylinder head and the engine blocksurface.

2. Install the new cylinder head gasket (A) and thedowel pins (B) on the engine block. Always use anew cylinder head gasket.

3. Check that the crankshaft keyway is facing up.

4. Install the cylinder head on the engine block.

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

6. If either diameter is less than 10.6 mm (0.42 in.),replace the cylinder head bolt.

(contd)

06/09/19 10:42:46 61SNC010_060_0045

6-46

Cylinder Head

Cylinder Head Installation (contd)

A

130

6 x 1.0 mm12 Nm (1.2 kgfm, 8.7 lbfft)

A

7. Apply new engine oil to the threads and flange ofall cylinder head bolts. Be sure to install the165 mm long head bolt (A) in the location shown.

8. Tighten the cylinder head bolts in sequence to29 Nm (3.0 kgfm, 22 lbfft), use a beam-typetorque wrench. When using a preset-type torquewrench, be sure to tighten slowly and do notovertighten. If a bolt makes any noise while you aretorquing it, loosen the bolt and retighten it from thefirst step.

9. Tighten all cylinder head bolts an additional 130 .

NOTE: Remove the cylinder head bolt if youtightened it beyond the specified angle, and goback to step 5 of the procedure.

10. Install the cam chain guide mounting top bolt.

11. Install the cam chain around the camshaft sprocketaligned with the reference mark (A), then install thecamshaft sprocket on the camshaft.

06/09/19 10:42:47 61SNC010_060_0046

Specified Torque: 56 Nm (5.7 kgfm, 41 lbfft)

6-47

A

B

12. Hold the camshaft with an open-end wrench, thentighten the bolt.

13. Loosely install the crankshaft pulley.



16. Turn the camshaft clockwise to compress the camchain tensioner, then remove the 6 x 1.0 mm bolt(B).


(4.5 kgfm, 33 lbfft), when turning the camshaft. Do not turn the camshaft counterclockwise.


18. Remove any old liquid gasket from the chain casemating surfaces, bolts, and bolt holes.


(contd)

06/09/19 10:42:48 61SNC010_060_0047

6-48

Cylinder Head


BA

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

8 x 1.25 mm31 Nm(3.2 kgfm, 23 lbfft)

AC

B

20. Apply liquid gasket, P/N 08717-0004, 08718-0001,08718-0003, or 08718-0009, evenly to the cylinderhead and engine block mating surface of the chaincase. Install the component within 5 minutes ofapplying the liquid gasket (see step 13 on page6-18).



engine block upper surface contact areas (B) onthe chain case.

If you apply liquid gasket P/N 08718-0012, thecomponent must be installed with 4 minutes.

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

21. Apply liquid gasket, P/N 08718-0001, or 08718-0009evenly to the oil pan mating surface of the chaincase. Install the component within 5 minutes ofapplying the liquid gasket.



shaded area (B). If you apply liquid gasket P/N 08718-0012, the



22. Set the edge of the chain case (A) to the edge of theoil pan (B), then install the chain case on the engineblock (C). Wipe off the excess liquid gasket on theoil pan and chain case mating area.

NOTE: When installing the chain case, do not slidethe bottom surface on the oil pan mounting surface.

06/09/19 10:42:49 61SNC010_060_0048

6-49

A

D

CB

6 x 1.0 mm9.8 Nm(1.0 kgfm, 7.2 lbfft)

C

B

D

A

D

C

E

A6 x 1.0 mm9.8 Nm (1.0 kgfm, 7.2 lbfft)

B6 x 1.0 mm12 Nm (1.2 kgfm, 8.7 lbfft)

23. Install the dipstick tube (A) with a new O-ring (B).Connect the crankshaft position (CKP) sensorconnector (C) and the harness clamps (D).

24. Install the side engine mount bracket, then tightenthe mounting nuts in the numbered sequenceshown (see step 16 on page 6-19).

25. Install the ground cable (see step 17 on page 6-19).


27. Install the warm-up three way catalytic converter(WU-TWC) and the under-floor three way catalyticconverter (TWC) (see step 26 on page 5-16).


29. Install the water pump (see page 10-5).


31. Install the upper radiator hose (A), the lowerradiator hose (B), the water bypass hose (C), andthe heater hoses (D).

32. Install the purge control solenoid stay bolts (A) andthe fuel pipe nut (B), then connect the purge joint tothe clamp stay (C).

33. Install the clip (D), then connect the purge controlsolenoid valve connector (E).

(contd)

06/09/19 10:42:51 61SNC010_060_0049

6-50

Cylinder Head


A B

C

D

CA

6 x 1.0 mm12 Nm(1.2 kgfm, 8.7 lbfft)

B

34. Install the harness clamp (A), then connect thecamshaft position (CMP) sensor (B) and the enginecoolant temperature (ECT) sensor 1 connector (C).

35. Install the connecting pipe (A) with a new O-ring (B).Install the harness clamp (C), then connect theknock sensor connector (D).

36. Install the intake manifold (see page 9-5).

37. Install the air cleaner assembly (see page 11-381).

38. After installation, check that all tubes, hoses, andconnectors are installed correctly.

39. Inspect for fuel leaks. Turn the ignition switchON (II) (do not operate the starter) so the fuel pumpruns for about 2 seconds and pressurizes the fuelline. Repeat this operation two or three times, thencheck for fuel leakage at any point in the fuel line.

40. Refill the radiator with engine coolant, and bleedthe air from the cooling system with the heatervalve open (see step 8 on page 10-7).

41. Do the CKP pattern clear/CKP pattern learnprocedure (see page 11-4).

42. Inspect the idle speed (see page 11-342).

43. Inspect the ignition timing (see page 4-18).

Replace.

06/09/19 10:42:51 61SNC010_060_0050

61snc01_06 - engine mechanical - cylinder head

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