Honda_Element_2003-2006

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Drain the cooling system and engine oil.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative and then positive battery cables
     
    Accessory drive belt
     
    Engine appearance cover
     
    Breather pipe and brake booster vacuum line
     
    Air cleaner and intake air duct
     
    Throttle cable linkage
     
    Brake booster vacuum hose
     
    EVAP canister hose
     
    Heater hoses
     
    Engine wire harness connectors and clamps from the cylinder head and intake manifold
     
    PCV valve
     
    Fuel lines
     
    Cylinder head cover
     
    Intake manifold
     
    Radiator hoses
     
    Catalytic converter
     
    Dipstick
     
    Cam chain tensioner by loosening the bolt in sequence one turn at a time.
     
    Cylinder head plug
     
    Timing chain
     

  8.  
  9. Hold the camshaft with an open end wrench, then remove the camshaft sprocket bolt.
  10.  
  11. Remove the camshaft sprocket.
  12.  
  13. Remove the engine mount bracket bolt on the cylinder head side.
  14.  
  15. Loosen the cylinder head bolts in sequence and 1 / 3 turns until all bolts are loose.
  16.  
  17. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Insight

  18.  

To install:

  1. Clean the cylinder head and block mating surfaces.
  2.  
  3. Ensure the crankshaft pulley is at TDC.
  4.  
  5. Apply liquid gasket to the areas of the engine block as shown.

    Click image to see an enlarged view

    Fig. Engine block sealant application areas-Insight



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Insight

  6.  
  7. Install the cylinder head.
  8.  
  9. Coat the cylinder head bolt threads with clean engine oil.
  10.  
  11. Tighten the cylinder head bolts in the sequence shown to 29 ft. lbs. (39 Nm), plus an additional 90 degrees.
  12.  
  13. Tighten the 6 mm bolts (A) to 105 inch lbs. (12 Nm).
  14.  
  15. Install the timing chain on the camshaft sprocket and place the sprocket on the camshaft.
  16.  
  17. Turn the camshaft sprocket counterclockwise to relieve the free play and check that the TDC mark on the sprocket lines up with the cylinder head surface.
  18.  
  19. If the mark is not aligned correctly, remove the sprocket from the camshaft and reposition the timing chain until the mark is aligned.
  20.  
  21. Hold the camshaft with an open end wrench and tighten the sprocket bolt to 41 ft. lbs. (56 Nm).
  22.  
  23. Install a new cylinder head plug.
  24.  
  25. Press the rod to pump the oil out of the timing chain tensioner.
  26.  
  27. Install a new o-ring to the tensioner spacer and a new gasket on the tensioner and then tighten the bolts and nuts equally to 105 inch lbs. (12 Nm), while pressing the tensioner against the head.
  28.  
  29. Adjust the valve clearance.
  30.  
  31. The remainder of the installation is the reverse of the removal procedure.
  32.  
  33. Start the engine and hold at 3500 rpm with no load for 10 minutes.
  34.  
  35. Check that the IMA battery level indicator reads full.
  36.  
  37. Check the engine idle.
  38.  

 
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