Honda_Odyssey_2001-2006

Cylinder Head

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Removal & Installation



J35a1 & J35a4 Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Evaporative Emissions (EVAP) control canister hose and vacuum hose
     
    Air intake tube
     
    Ignition coil covers
     
    Intake manifold cover
     
    Accelerator cable
     
    Cruise control cable
     
    Fuel lines
     
    Brake booster vacuum line
     
    Intake manifold vacuum line
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Side engine mount bracket
     
    Power steering pump
     
    Power steering hose clamp
     
    Alternator
     
    Intake Air Temperature (IAT) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Radiator fan switch connectors
     
    ECT gauge sending unit connector
     
    Crankshaft Position (CKP) sensor connector
     
    Top Dead Center (TDC) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Variable Valve Timing and Valve Lift Electronic Control (VTEC) solenoid valve connector
     
    VTEC oil pressure switch connector
     
    Oil pressure switch connector
     
    Ignition coils
     
    Intake manifold
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Fuel injection air control valve vacuum lines
     
    Front cover
     
    Timing belt. Refer to the timing belt procedure.
     
    Radiator hoses
     
    Heater hoses
     
    Front and rear exhaust manifolds
     
    Coolant cross-over pipe
     
    Valve covers
     

  8.  
  9. Loosen the cylinder head bolts in sequence and 1 / 3 turns until all bolts are loose.
  10.  
  11. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-J35A4 engine



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head assembly and related components-J35A4 engine

  12.  

To install:

  1. Align the crankshaft and camshaft sprocket TDC marks. See the Timing Belt Procedure.
  2.  
  3. Install the cylinder heads with new gaskets.
  4.  
  5. Apply clean engine oil to the cylinder head bolt threads and flanges.
  6.  
  7. Tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 29 ft. lbs. (39 Nm)
    2.  
    3. Step 2: 51 ft. lbs. (69 Nm)
    4.  
    5. Step 3: 72 ft. lbs. (98 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-J35A4

    6.  

  8.  
  9. Install or connect the following:

    Valve covers
     
    Coolant cross-over pipe
     
    Front and rear exhaust manifolds
     
    Heater hoses
     
    Radiator hoses
     
    Timing belt
     
    Front cover
     
    Fuel injection air control valve vacuum lines
     
    Fuel supply manifold
     
    Fuel injector connectors
     
    Intake manifold
     
    Ignition coils
     
    Oil pressure switch connector
     
    VTEC oil pressure switch connector
     
    VTEC solenoid valve connector
     
    EGR connector
     
    TDC sensor connector
     
    CKP sensor connector
     
    ECT gauge sending unit connector
     
    Radiator fan switch connectors
     
    ECT sensor connector
     
    MAP sensor connector
     
    TP sensor connector
     
    IAC valve connector
     
    IAT sensor connector
     
    Alternator
     
    Power steering hose clamp
     
    Power steering pump
     
    Side engine mount bracket
     
    PCV valve and hose
     
    Intake manifold vacuum line
     
    Brake booster vacuum line
     
    Fuel lines
     
    Cruise control cable
     
    Accelerator cable
     
    Intake manifold cover
     
    Ignition coil covers
     
    Accessory drive belts
     
    Air intake tube
     
    EVAP control canister hose and vacuum hose
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
  14.  

J35a6 Engine

NOTE
The engine coolant temperature must be below 100°F (38°C) before removing the head bolts.

  1. Make sure that you have the anti-theft codes for the radio and navigation system.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the battery ground.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Drain the coolant.
  10.  
  11. Remove the power steering pump and the hose bracket.
  12.  
  13. Remove the alternator.
  14.  
  15. Remove the timing belt.
  16.  
  17. Remove the intake manifold.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Tag and disconnect all wiring from the head.
  22.  
  23. Remove the front and rear warm-up converters.
  24.  
  25. Disconnect the fuel feed line.
  26.  
  27. Remove the wiring harness bracket.
  28.  
  29. Remove the upper and lower radiator hoses.
  30.  
  31. Remove the heater and bypass hoses.
  32.  
  33. Remove the EVAP canister hose joint bracket.
  34.  
  35. Remove the harness brackets from the front and rear heads.
  36.  
  37. Remove the fuel rail.
  38.  
  39. Remove the water passage assembly.
  40.  
  41. Remove the camshaft pulley.
  42.  
  43. Remove the cylinder head cover.
  44.  
  45. Remove the head bolts in the sequence shown 1 / 3 turn at a time.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-J35A6 engine

  46.  
  47. Remove the head.
  48.  

To install:

  1. Clean all mating surfaces thoroughly.
  2.  
  3. Clean and install the oil control orifices with new O-rings.
  4.  
  5. Install the dowel pins and a new head gasket.
  6.  
  7. Set the crankshaft pulley to TDC by aligning the TDC mark (A) with the pointer (B). See the Timing Belt Procedure.
  8.  
  9. Set the camshaft pulley(s) to TDC by aligning the mark (A) with the pointer (B). See the Timing Belt Procedure.
  10.  
  11. Coat the threads and flanges of head bolts with clean engine oil.
    WARNING
    There are 2 types of head bolts in service, 6-point and 12-point. Do not mix them on the same head.


    NOTE
    There are 2 different tightening methods based on which type of head bolt is used.


    WARNING
    When tightening the bolts, tighten them slowly. If any bolt makes a noise while tightening, loosen the bolt and retighten from Step 1.



    Click image to see an enlarged view

    Fig. Head bolt torque sequence-J35A6 engine

  12.  
  13. For 6-points bolts, tighten the bolts, in sequence, in 3 steps. Perform each step twice.

    Step 1: 29 ft. lbs. (39 Nm)
     
    Step 2: 51 ft. lbs. (69 Nm)
     
    Step 3: 72 ft. lbs. (98 Nm)
     

  14.  
  15. For 12-point bolts:

    Step 1: Torque all bolts in sequence to 22 ft. lbs.
     
    Step 2: Torque all bolts in sequence an additional 90°
     
    Step 3: Torque all bolts in sequence an additional 90°
     
    If new bolts are used, torque them in sequence an additional 90°
     

  16.  
  17. The remainder of installation is the reverse of removal. Note the following torques:

    Water passage 8mm bolts: 16 ft. lbs. (22 Nm)
     
    Water passage 6mm bolts: 105 inch lbs. (12 Nm)
     
    Front head bracket 10mm bolt: 33 ft. lbs. (44 Nm)
     
    Rear head bracket 8mm bolt: 16 ft. lbs. (22 Nm)
     
    EVAP canister joint bracket: 105 inch lbs. (12 Nm)
     
    Power steering pump bolts: 16 ft. lbs. (22 Nm)
     

  18.  

J35a7 Engine

NOTE
The engine coolant temperature must be below 100°F (38°C) before removing the head bolts.

  1. Make sure that you have the anti-theft codes for the radio and navigation system.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the battery ground.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Drain the coolant.
  10.  
  11. Remove the power steering pump and the hose bracket.
  12.  
  13. Remove the alternator.
  14.  
  15. Remove the timing belt.
  16.  
  17. Remove the intake manifold.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Tag and disconnect all wiring from the head.
  22.  
  23. Remove the front and rear warm-up converters.
  24.  
  25. Disconnect the fuel feed line.
  26.  
  27. Remove the wiring harness bracket.
  28.  
  29. Remove the upper and lower radiator hoses.
  30.  
  31. Remove the heater and bypass hoses.
  32.  
  33. Remove the EVAP canister hose joint bracket.
  34.  
  35. Remove the harness brackets from the front and rear heads.
  36.  
  37. Remove the fuel rail.
  38.  
  39. Remove the water passage assembly.
  40.  
  41. Remove the camshaft pulley.
  42.  
  43. Remove the cylinder head cover.
  44.  
  45. Remove the head bolts in the sequence shown 1 / 3 turn at a time.

    Click image to see an enlarged view

    Fig. Front cylinder head bolt removal sequence-J35A7 engine



    Click image to see an enlarged view

    Fig. Rear cylinder head bolt removal sequence-J35A7 engine

  46.  
  47. Remove the head.
  48.  

To install:

  1. Clean all mating surfaces thoroughly.
  2.  
  3. Clean and install the oil control orifices with new O-rings.
  4.  
  5. Install the dowel pins and a new head gasket.
  6.  
  7. Set the crankshaft pulley to TDC by aligning the TDC mark (A) with the pointer (B). See the Timing Belt Procedure.
  8.  
  9. Set the camshaft pulley(s) to TDC by aligning the mark (A) with the pointer (B). See the Timing Belt Procedure.
  10.  
  11. Coat the threads and flanges of head bolts with clean engine oil.
    WARNING
    When tightening the bolts, tighten them slowly. If any bolt makes a noise while tightening, loosen the bolt and retighten from Step 1.



    Click image to see an enlarged view

    Fig. Front head bolt torque sequence-J35A7 engine



    Click image to see an enlarged view

    Fig. Rear head bolt torque sequence-J35A7 engine

  12.  
  13. Tighten the bolts, in sequence, in 3 steps. Perform each step twice.

    Step 1: 29 ft. lbs. (39 Nm)
     
    Step 2: 51 ft. lbs. (69 Nm)
     
    Step 3: 72 ft. lbs. (98 Nm)
     

  14.  
  15. The remainder of installation is the reverse of removal. Note the following torques:

    Water passage 8mm bolts: 16 ft. lbs. (22 Nm)
     
    Water passage 6mm bolts: 105 inch lbs. (12 Nm)
     
    Front head bracket 10mm bolt: 33 ft. lbs. (44 Nm)
     
    Rear head bracket 8mm bolt: 16 ft. lbs. (22 Nm)
     
    EVAP canister joint bracket: 105 inch lbs. (12 Nm)
     
    Power steering pump bolts: 16 ft. lbs. (22 Nm)
     

  16.  

 
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