Honda Prelude Accord Civic S2000 2001-2006

Cylinder Head

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Removal & Installation




NOTE
The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery. If the vehicle is equipped with 4WS, the steering control unit is shut down when the battery is disconnected. After connecting the battery, turn the steering wheel lock-to-lock to reset the steering control unit.


NOTE
The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.

1.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Remove or disconnect the following: Negative battery cable

    Negative battery cable
     

  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
  10.  


NOTE
Label the wires before disconnecting them.



Ignition wires
 
Air intake duct and the air cleaner assembly
 

  1. Relieve the fuel pressure.
  2.  
  3. Clean up any fuel that may have spilled on the engine or intake manifold.
  4.  
  5. Remove or disconnect the following: Upper radiator hose from the coolant inletCoolant bypass hoses and the heater hose from the intake manifoldPower steering pump beltPower steering pump from its mounting bracket and lift the power steering reservoir from its mount. Move the pump and reservoir out of the work area and secure them. Don't disconnect the hydraulic lines.

    Upper radiator hose from the coolant inlet
     
    Coolant bypass hoses and the heater hose from the intake manifold
     
    Power steering pump belt
     
    Power steering pump from its mounting bracket and lift the power steering reservoir from its mount. Move the pump and reservoir out of the work area and secure them. Don't disconnect the hydraulic lines.
     

  6.  
  7. Place a block of wood on the pad of a floor jack. Place the floor jack under the engine for support.
  8.  
  9. Remove or disconnect the following: Left-front engine mount bracket, if equipped with air conditioning

    Left-front engine mount bracket, if equipped with air conditioning
     

  10.  


NOTE
Slip the air conditioning compressor belt around the engine mount to remove it.



Air conditioning compressor belt
 
Alternator belt
 

  1. Be sure the engine is supported with the padded floor jack. Loosen the nuts from left side engine mount. Remove the engine mount bracket.
  2.  
  3. Remove or disconnect the following: Valve cover and the upper timing belt coverCrankshaft pulley and the lower timing belt coverDipstick tube from its catches on the timing coverTiming belt.

    Valve cover and the upper timing belt cover
     
    Crankshaft pulley and the lower timing belt cover
     
    Dipstick tube from its catches on the timing cover
     
    Timing belt.
     

  4.  
  5. With the timing belt removed, inspect the water pump and replace it if necessary.
  6.  
  7. Remove or disconnect the following: Distributor, if equippedCamshaft sprocketFuel lines from the intake manifold fuel rail. Immediately plug the lines to prevent fuel leakage and contaminationThrottle cable from the linkage by first loosening its locknut, then slipping it out of its holder.

    Distributor, if equipped
     
    Camshaft sprocket
     
    Fuel lines from the intake manifold fuel rail. Immediately plug the lines to prevent fuel leakage and contamination
     
    Throttle cable from the linkage by first loosening its locknut, then slipping it out of its holder.
     

  8.  


NOTE
Label the electrical connectors, before disconnecting them.



Fuel injector wiring harness connectors
 
VTEC solenoid valve and pressure switch connectors, if equipped
 
Idle Air Control (IAC) valve connector
 
Throttle Position (TP) sensor connector
 
Exhaust Gas Recirculation (EGR) valve lift sensor connectors, if equipped
 
Engine Coolant Temperature (ECT) sensor, switch, and gauge sender connectors
 
Manifold Absolute Pressure (MAP) sensor connector
 
Primary and secondary Heated Oxygen Sensor (HO2S) connectors
 
Vacuum hoses and Positive Crankcase Ventilation (PCV) hose from the intake manifold and throttle body
 
EVAP and breather hoses from the intake manifold
 
Intake manifold together with the throttle body and plenum
 
Exhaust manifold
 
Power steering pump bracket
 

  1. Loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence. Start with the outermost bolts and work toward the middle of the cylinder head. Loosen the bolts in the reverse order of installation.
  2.  
  3. Remove the cylinder head. If the head sticks to the engine block, tap it with a plastic or wooden mallet.
  4.  
  5. Inspect the cylinder head for warpage and cracking. Repair, machine, or replace as necessary. The warpage limit is 0.002 in. (0.05mm). Standard cylinder head height is 3.659-3.663 in. (92.95-93.05mm).
  6.  
  7. Remove the old cylinder head gasket and thoroughly clean the mating surfaces.
  8.  
  9. Cover the engine block with a sheet of plastic to keep out dust and foreign objects.
  10.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Install or connect the following: New head gasket onto the engine blockCamshaft, if removed, with the keyway facing up so that the engine will remain at Top Dead Center (TDC)/compression for the No. 1 cylinderNew lubricated camshaft seal

    New head gasket onto the engine block
     
    Camshaft, if removed, with the keyway facing up so that the engine will remain at Top Dead Center (TDC)/compression for the No. 1 cylinder
     
    New lubricated camshaft seal
     

  6.  


NOTE
Use new cylinder head bolts and washers. Used or previously-tightened bolts may be stretched, and therefore they have reduced clamping and sealing power under compression. Apply clean engine oil to the threads of each head bolt.



Cylinder head into position
 
Cylinder head bolts and hand-tighten
 

  1. Tighten the cylinder head bolts to their final torque specification in 4 steps. Use a crisscross sequence starting with the bolts at the middle of the head and working toward the outer bolts as follows: Step 1: Tighten each bolt to 14 ft. lbs. (20 Nm).Step 2: Tighten each bolt to 36 ft. lbs. (49 Nm).Step 3: Tighten each bolt to 49 ft. lbs. (67 Nm).Step 4: Retighten only the 2 center bolts to 49 ft. lbs. (67 Nm).
    1. Step 1: Tighten each bolt to 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Tighten each bolt to 36 ft. lbs. (49 Nm).
    4.  
    5. Step 3: Tighten each bolt to 49 ft. lbs. (67 Nm).
    6.  
    7. Step 4: Retighten only the 2 center bolts to 49 ft. lbs. (67 Nm).
    8.  

  2.  
  3. Apply oil to the camshaft sprocket bolt. Install the sprocket with the UP mark and the keyway pointing straight up. Tighten the sprocket bolt to 27 ft. lbs. (37 Nm).
  4.  
  5. Install or connect the following: Intake manifold with a new gasket, and tighten the nuts in a crisscross pattern in 2 or 3 steps to 17 ft. lbs. (24 Nm) starting with the inner nutsBolts that secure the intake manifold to its bracket: 17 ft. lbs. (24 Nm)Power steering pump bracket: 33 ft. lbs. (44 Nm)Exhaust manifold with a new gasket. Apply anti-seize paste to the studs, and tighten the nuts to 23 ft. lbs. (31 Nm) in a crisscross sequence.Exhaust manifold to the front exhaust pipe. Tighten the self-locking nuts to 25 ft. lbs. (33 Nm). On vehicles with the D16Y8 engine, tighten the nuts to 40 ft. lbs. (55 Nm).

    Intake manifold with a new gasket, and tighten the nuts in a crisscross pattern in 2 or 3 steps to 17 ft. lbs. (24 Nm) starting with the inner nuts
     
    Bolts that secure the intake manifold to its bracket: 17 ft. lbs. (24 Nm)
     
    Power steering pump bracket: 33 ft. lbs. (44 Nm)
     
    Exhaust manifold with a new gasket. Apply anti-seize paste to the studs, and tighten the nuts to 23 ft. lbs. (31 Nm) in a crisscross sequence.
     
    Exhaust manifold to the front exhaust pipe. Tighten the self-locking nuts to 25 ft. lbs. (33 Nm). On vehicles with the D16Y8 engine, tighten the nuts to 40 ft. lbs. (55 Nm).
     

  6.  
  7. Verify that the engine is at Top Dead Center (TDC)/compression for the No. 1 cylinder.
  8.  
  9. Install or connect the following: Timing belt. After the timing belt has been properly tensioned, tighten the adjusting bolt to 33 ft. lbs. (44 Nm).Lower timing belt coverCrankshaft pulley; tighten its bolt to 134 ft. lbs. (181 Nm)Dipstick tube back into its catches

    Timing belt. After the timing belt has been properly tensioned, tighten the adjusting bolt to 33 ft. lbs. (44 Nm).
     
    Lower timing belt cover
     
    Crankshaft pulley; tighten its bolt to 134 ft. lbs. (181 Nm)
     
    Dipstick tube back into its catches
     

  10.  
  11. Adjust the valves. If equipped with a VTEC engine, also check the rocker arms for free and smooth motion..
  12.  
  13. If equipped with a VTEC engine, remove the VTEC solenoid valve and its filter. Install a new filter, then reinstall the VTEC solenoid valve and tighten its bolt to 108 inch lbs. (12 Nm).
  14.  
  15. Install or connect the following: Distributor, if equipped

    Distributor, if equipped
     

  16.  
  17. Be sure all the spark plug tube sealing gaskets are fully seated.
  18.  
  19. Install or connect the following: New gasket onto to the valve cover. Apply liquid gasket to the corner recesses of the gasket. Don't let the sealant cure before installing the valve cover onto the cylinder head.Valve cover. Gently wiggle the valve cover to be sure it is fully seated. Tighten the valve cover bolts in a crisscross pattern to 84 inch lbs. (10 Nm).New spark plugsIgnition wiresUpper radiator hose, heater hoses, and intake manifold coolant bypass hosesIntake manifold vacuum lines, PCV, EVAP canister, and breather hosesFuel lines to the fuel rail. Use new sealing washers on the banjo fitting. Carefully tighten the banjo fitting to 21 ft. lbs. (28 Nm) for the D16Y5 engine, or to 16 ft. lbs. (22 Nm) for all other engines. Tighten the service bolt to 10-11 ft. lbs. (13-15 Nm).Throttle cable. Adjust its tension so the cable has a deflection of 10-12mm (0.39-0.47 in.).

    New gasket onto to the valve cover. Apply liquid gasket to the corner recesses of the gasket. Don't let the sealant cure before installing the valve cover onto the cylinder head.
     
    Valve cover. Gently wiggle the valve cover to be sure it is fully seated. Tighten the valve cover bolts in a crisscross pattern to 84 inch lbs. (10 Nm).
     
    New spark plugs
     
    Ignition wires
     
    Upper radiator hose, heater hoses, and intake manifold coolant bypass hoses
     
    Intake manifold vacuum lines, PCV, EVAP canister, and breather hoses
     
    Fuel lines to the fuel rail. Use new sealing washers on the banjo fitting. Carefully tighten the banjo fitting to 21 ft. lbs. (28 Nm) for the D16Y5 engine, or to 16 ft. lbs. (22 Nm) for all other engines. Tighten the service bolt to 10-11 ft. lbs. (13-15 Nm).
     
    Throttle cable. Adjust its tension so the cable has a deflection of 10-12mm (0.39-0.47 in.).
     

  20.  
  21. Installation of the remaining components is the reverse of removal.
  22.  

2.0L Engine
2.2L Engine
2.3L Engine
2.4L Engine
3.0L Engine
Accord
2.3L Engine
  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
     
    Air intake duct
     
    Throttle and cruise control cables
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Fuel lines
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) canister hoses
     
    Water bypass hoses
     
    Accessory drive belts
     
    Power steering pump
     
    Alternator wiring harness
     
    Radiator hoses
     
    Heater hoses
     
    Fuel injector connectors
     
    Intake Air Temperature (IAT) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector (F23A1, F23A5 engines)
     
    Air/Fuel ratio sensor connector (F23A4 engine)
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Radiator fan switch connector
     
    Coolant temperature gauge sender connector
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Crankshaft Position (CKP) sensor connector
     
    VTEC solenoid valve connector (F23A1, F23A4 engines)
     
    VTEC oil pressure switch connector (F23A1, F23A4 engines)
     
    Distributor
     
    Front motor mount bracket
     
    Valve cover
     
    Timing belt
     
    Camshaft pulley and back cover
     
    Intake manifold
     
    Exhaust manifold
     
    Cylinder head. Loosen the bolts in sequence and in 1/3 turns.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.3L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Set the crankshaft to TDC by aligning pointers A and B-2.3L engine



Click image to see an enlarged view

Fig. Align the camshaft pulley as shown prior to cylinder head installation-2.3L engine



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.3L engine

  1. Set the crankshaft pulley to Top Dead Center (TDC).
  2.  
  3. Set the camshaft pulley to TDC.
  4.  
  5. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
    1. Step 1: 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Plus 90 degrees.
    6.  
    7. Step 4: If using new cylinder head bolts, add an additional 90 degrees.
    8.  

  6.  
  7. The remainder of the installation is the reverse of the removal procedure.
  8.  

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant. Remove the drive belt.
  6.  
  7. Disconnect the intake air temperature sensor. Remove the vacuum hose and breather pipe. Remove the intake air duct. Remove the quick connect fitting cover. Disconnect the fuel feed hose.
  8.  
  9. Remove the intake manifold. Remove the exhaust manifold.
  10.  
  11. Remove the bolt securing the connecting pipe. Remove the water bypass hose. Remove the evaporative emission canister hose and power brake vacuum hose.
  12.  
  13. Remove the PCV valve hose. Remove the ground cable. Remove the upper radiator hose and the heater hoses.
  14.  
  15. Remove the engine wiring harness connectors and the wire harness clamps from the cylinder head.
  16.  
  17. Disconnect the fuel injector connectors, engine coolant temperature sensor connector, camshaft position sensor connectors and the EGR valve connector.
  18.  
  19. Disconnect the rocker arm oil control solenoid connector and engine oil pressure sensor connector.
  20.  
  21. Remove the two bolts securing the EVAP canister purge valve bracket and remove the bolt securing the harness bracket.
  22.  
  23. Remove the cam chain. Remove the rocker arm assembly.
  24.  
  25. Remove the cylinder head retaining bolts. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.4L engines

  26.  
  27. Remove the cylinder head from the engine.
  28.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Set the crankshaft to TDC. Align the TDC mark on the crankshaft sprocket with the pointer on the engine block.

    Click image to see an enlarged view

    Fig. Set the crankshaft to TDC by aligning the mark (A) on the crankshaft sprocket with the pointer (B) on the cylinder block-2.4L engine

  6.  
  7. Position the cylinder head on the engine.
  8.  
  9. Measure the diameter of each cylinder head bolt at points A & B, as shown in the illustration. If either diameter is less than 0.42 in. (10.6mm), replace the head bolt

    Click image to see an enlarged view

    Fig. You must measure the cylinder head bolts to see if they can be reused or need to be replaced-2.4L engine

  10.  
  11. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2.4L engine

  12.  
  13. Continue the installation in the reverse order of the removal procedure.
  14.  
  15. Reprogram the ECM/PCM with the HDS, turn the ignition switch the OFF position. Turn the ignition switch to the ON position. Wait thirty seconds. Turn the ignition switch OFF and disconnect the HDS from the DLC.
  16.  
  17. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  18.  
  19. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 176 degrees.
  20.  
  21. Let the engine idle for about five minutes with the throttle fully closed.
  22.  
  23. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  24.  
  25. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  26.  
  27. Reprogram the power window control unit as follows.
  28.  
  29. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  30.  
  31. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  32.  
  33. Repeat the above step three more times. Wait one second.
  34.  
  35. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  36.  
  37. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  38.  
  39. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  40.  
  41. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  42.  
  43. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  44.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant. Remove the drive belt. Remove the air cleaner.
  6.  
  7. Remove the timing belt. Remove the power steering pump and hose clamp. Remove the alternator.
  8.  
  9. Remove the intake manifold. Remove the six ignition coils.
  10.  
  11. Remove the engine wire harness connectors and wire harness from the cylinder head.
  12.  
  13. Disconnect the six fuel injector connectors, engine coolant temperature sensor connector, crankshaft position sensor connector, and the EGR valve sensor connector.
  14.  
  15. Disconnect the rocker arm oil control solenoid connector, rocker arm oil pressure switch connector, and the two air fuel ratio sensor connectors. Disconnect the secondary heated oxygen sensor connectors.
  16.  
  17. Remove the upper and lower radiator hoses and the heater hoses. Remove the water bypass hose.
  18.  
  19. Remove the ground cable. Remove the bolt securing the harness bracket. Remove the fuel rails. Remove the bolt securing the harness bracket.
  20.  
  21. Remove the front and rear three way catalytic converter. Remove the water passage.
  22.  
  23. Remove the front and rear camshaft pulleys and front and rear back covers.
  24.  
  25. Remove the cylinder head covers.
  26.  
  27. Remove the cylinder head retaining bolts. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-3.0L engine

  28.  
  29. Remove the cylinder head from the engine.
  30.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Set the timing belt drive pulley to TDC by aligning the TDC mark on the tooth of the timing belt drive pulley with the pointer on the oil pump.
  6.  
  7. Set the camshaft pulleys to TDC by aligning the TDC marks on the camshaft pulleys with the pointers on the back covers
  8.  
  9. Position the cylinder head on the engine.
  10.  
  11. If the head bolts are Dodecagon type, measure the diameter of each cylinder head bolt between point A and B, see illustration. If either diameter is less than 0.42 inch, replace the bolt.
  12.  
  13. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.0L engine

  14.  
  15. Continue the installation in the reverse order of the removal procedure.
  16.  
  17. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  18.  
  19. Reprogram the power window control unit as follows.
  20.  
  21. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  22.  
  23. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  24.  
  25. Repeat the above step three more times. Wait one second.
  26.  
  27. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  28.  
  29. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  30.  
  31. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  32.  
  33. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  34.  
  35. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  36.  

Civic
2001-05 Models 1.7L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant.
  6.  
  7. Remove the throttle cable and the cruise control actuator cable. Remove the intake resonator.
  8.  
  9. Disconnect the intake air temperature (IAT) sensor. Remove the breather hose and the air cleaner assembly. Remove the brake booster vacuum hose and the PCV valve hose.
  10.  
  11. Remove the evaporative emission (EVAP) canister hose. Remove the ground cable. Remove the upper and lower radiator hoses. Remove the heater hoses and the water bypass hose.
  12.  
  13. Remove the two bolts securing the connecting pipe and remove the pipe from the water passage.
  14.  
  15. Remove the adjusting plate mounting bolt, locknut and mounting bolt. Remove the power steering pump belt. Remove the pump and position it to the side without disconnecting the hoses.
  16.  
  17. Remove the alternator. Remove the air conditioning hose bracket. Remove the power steering hose bracket.
  18.  
  19. Remove the engine wiring harness connectors and wire harness clamps from the intake manifold.
  20.  
  21. Remove the idle air control valve connector, throttle position sensor connector, evaporative emission control canister connector and the engine coolant temperature sensor connector.
  22.  
  23. Remove the radiator fan switch connector, crankshaft position sensor connector, camshaft position sensor connector and the camshaft position TDC sensor connector.
  24.  
  25. Remove the EGR connectors, VTEC solenoid valve connector and VETC oil pressure switch connector, except Civic GL. Remove the oil pressure sensor connector.
  26.  
  27. Properly support the engine under the oil pan. Remove the upper bracket. Remove the exhaust manifold cover. Remove the exhaust manifold.
  28.  
  29. Remove the intake manifold retaining bolts and remove the intake manifold.
  30.  
  31. Remove the four ignition coils. Remove the throttle cable clamps and harness holder from the cylinder head cover.
  32.  
  33. Remove the cylinder head cover retaining bolts. Remove the cylinder head cover.
  34.  
  35. Remove the timing belt. Remove the camshaft pulley and back cover from the cylinder head.
  36.  
  37. Remove the cylinder head retaining bolts.
  38.  
  39. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.
  40.  
  41. Remove the cylinder head from the engine.
  42.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Set the crankshaft to TDC. Align the TDC mark on the timing belt drive pulley with the pointer on the oil pump.
  6.  
  7. Set the camshaft pulley to TDC. The UP mark on the camshaft pulley should be at the top. Align the TDC marks on the camshaft pulley with the top edge of the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-1.7L engine

  8.  
  9. Position the cylinder head on the engine. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Enter the antitheft codes for the radio and the navigation system.
  14.  
  15. Reprogram the ECM/PCM engine idle characteristics. Be sure all electrical items are OFF.
  16.  
  17. Start the engine. Hold the idle speed at 3000 RPM-s in park or neutral until the radiator fan comes on or the temperature reached 194 degrees.
  18.  
  19. Let the engine idle for about five minutes with the throttle fully closed.
  20.  
  21. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  22.  
  23. Set the clock.
  24.  

2006 Models 1.8L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant.
  6.  
  7. Remove the drive belt. Remove the intake manifold.
  8.  
  9. Remove the harness clamps. Remove the PCV valve hose from the clamp. Remove the air cleaner housing bracket and the harness holder from the cylinder head.
  10.  
  11. If equipped with manual transaxle, remove the upper radiator hose and heater hoses.
  12.  
  13. If equipped with automatic transaxle, remove the upper radiator hose, heater hoses and water bypass hose.
  14.  
  15. Remove the engine wiring harness connectors and the wiring harness clamps from the cylinder head.
  16.  
  17. Remove the injector connectors, coolant temperature connector, air fuel ratio sensor connector and the secondary heated oxygen sensor connector.
  18.  
  19. Disconnect the EGR valve connector, rocker arm oil control solenoid sensor and the rocker arm oil pressure switch connector.
  20.  
  21. Remove the four ignition coils. Remove the three way catalytic converter. Remove the thermostat housing.
  22.  
  23. Remove the cam chain. Remove the cylinder head retaining bolts.
  24.  
  25. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.
  26.  
  27. Remove the cylinder head from the engine.
  28.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Set the crankshaft to TDC. Align the TDC mark on the crankshaft sprocket with the pointer on the engine block.
  6.  
  7. Set the camshaft to TDC. The UP mark on the camshaft sprocket should be at the top and the TDC grooves on the camshaft sprocket should line up with the top edge of the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-1.8L engine

  8.  
  9. Position the cylinder head on the engine.
  10.  
  11. Measure the diameter of each cylinder head bolt between point A and B. If either diameter is less than 0.42 inch, replace the bolt.

    Click image to see an enlarged view

    Fig. Cylinder head bolt measurement reference points

  12.  
  13. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.
  14.  
  15. Continue the installation in the reverse order of the removal procedure.
  16.  
  17. Reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  18.  
  19. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  20.  
  21. Stop the vehicle, but keep the engine running.
  22.  
  23. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  24.  
  25. Stop the vehicle, but keep the engine running.
  26.  
  27. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  28.  
  29. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  30.  
  31. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  32.  
  33. Reprogram the power window control unit as follows.
  34.  
  35. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  36.  
  37. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  38.  
  39. Repeat the above step three more times. Wait one second.
  40.  
  41. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  42.  
  43. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  44.  
  45. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  46.  
  47. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  48.  
  49. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  50.  

2006 Models 2.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant.
  6.  
  7. Remove the air cleaner housing. Remove the drive belt. Remove the intake manifold.
  8.  
  9. Remove the exhaust manifold. Remove the evaporative emission canister hose and the brake booster vacuum hose.
  10.  
  11. Remove the quick-connect fitting cover. Disconnect the fuel feed hose. Remove the harness holder from the bracket then remove the harness holder bracket.
  12.  
  13. Remove the upper radiator hose and the heater hoses. Remove the bolt securing the connecting pipe.
  14.  
  15. Remove the fuel injector connectors, the engine coolant temperature sensor connector, the camshaft position intake sensor connector and the camshaft position exhaust sensor connector.
  16.  
  17. Remove the rocker arm oil control solenoid connector, the rocker arm oil pressure switch connector and the EVAP canister purge valve connector.
  18.  
  19. Remove the cam chain. Remove the rocker arm cover. Remove the rocker arm assembly. Remove the cylinder head retaining bolts.
  20.  
  21. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.
  22.  
  23. Remove the cylinder head from the engine.
  24.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Set the crankshaft to TDC. Align the TDC mark on the crankshaft sprocket with the pointer on the engine block.
  6.  
  7. Position the cylinder head on the engine.
  8.  
  9. Measure the diameter of each cylinder head bolt between point A and B. If either diameter is less than 0.42 inch, replace the bolt.
  10.  
  11. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.
  12.  
  13. Continue the installation in the reverse order of the removal procedure.
  14.  
  15. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  16.  
  17. Reprogram the power window control unit as follows.
  18.  
  19. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  20.  
  21. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  22.  
  23. Repeat the above step three more times. Wait one second.
  24.  
  25. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  26.  
  27. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  28.  
  29. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  30.  
  31. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  32.  
  33. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  34.  

Prelude
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Bring the No. 1 cylinder to TDC.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be careful not to bend the cable when removing. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one.


    NOTE
    Label the connectors before disconnecting them.


    NOTE
    Matchmark the installed position of the distributor before removal.


    NOTE
    Tag all vacuum hoses before disconnecting them.



    Vacuum hose, breather hose and air intake duct
     
    Water bypass hose from the cylinder head
     
    Fuel feed and return hose from the fuel rail
     
    Evaporative emissions (EVAP) control canister hose from the intake manifold
     
    Brake booster vacuum hose from the intake manifold
     
    Vacuum hose mount, on automatic transaxle equipped vehicles
     
    Throttle cable from the throttle body
     
    Throttle control cable from the throttle body, on automatic transaxle equipped vehicles
     



    Ignition coil
     



    Electrical connectors from the distributor and the spark plug wires from the spark plugs
     



    Distributor
     
    Ignition coil wire from the distributor
     
    Connector and the terminal from the alternator, then the engine wiring harness from the valve cover
     
    Fuel injector connectors
     
    Intake Air Temperature (IAT) sensor connector, if equipped
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Exhaust Gas Recirculation (EGR) valve lift sensor
     
    Ground cable terminals
     
    Engine Coolant Temperature (ECT) switch B connector, if equipped
     
    Heated Oxygen Sensor (HO 2 S) connector
     
    ECT sensor
     
    ECT gauge sending unit connector
     
    Crankshaft Position Sensor (CKP)/Cylinder Position (CYP) sensor connector, if equipped
     
    Vehicle Speed Sensor (VSS) connector
     
    ECT switch A connector
     
    Upper radiator hose and the heater inlet hose from the cylinder head
     
    Lower radiator hose and heater outlet hose from the intake manifold
     
    Bypass hose from the thermostat housing and intake manifold
     
    Thermostat. Discard the O-rings.
     



    Emissions vacuum hoses from the intake manifold assembly
     
    Cruise control actuator electrical connector and the vacuum tube, then the actuator
     
    Engine ground cable from the body
     
    Mounting bolts and drive belt from the power steering pump. Pull the pump away from the mounting bracket without disconnecting the hoses. Support the pump out of the way.
     

  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove or disconnect the following:
    NOTE
    To prevent warpage, unscrew the bolts in sequence 1 / 3 turn at a time. Repeat the sequence until all bolts are loosened.



    Front wheel and tire assemblies
     
    Splash shield
     
    Intake manifold bracket bolts
     
    Intake manifold
     
    Exhaust pipe from the exhaust manifold
     
    Exhaust manifold and the exhaust manifold heat insulator
     
    Power steering pump mounting bracket
     
    Positive Crankcase Ventilation (PCV) hose, then remove the cylinder head cover. Replace the rubber seals if damages or deteriorated.
     
    Timing belt.
     
    Cylinder head bolts in the reverse order of installation
     

  16.  
  17. Separate the cylinder head from the engine block with a suitable flat bladed prytool.
  18.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.2L engine

  1. Be sure all cylinder head and block gasket surfaces are clean. Check the cylinder head for warpage. If warpage is less than 0.002 in. (0.05mm), cylinder head resurfacing is not required. Maximum resurface limit is 0.008 in. (0.2mm) based on a cylinder head height of 3.94 in. (100mm).
  2.  
  3. Always use a new head gasket.
  4.  
  5. The UP mark on the camshaft pulley should be at the top.
  6.  
  7. Be sure the No. 1 cylinder is at Top Dead Center (TDC).
  8.  
  9. Clean the oil control orifice and install a new O-ring. Install and align the cylinder head dowel pins and oil control jet.
  10.  
  11. Install the bolts that secure the intake manifold to its bracket but do not tighten them.
  12.  
  13. Position the camshaft correctly.
  14.  
  15. Install the cylinder head, then tighten the cylinder head bolts sequentially in 3 steps:
    1. Step 1: 29 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 51 ft. lbs. (70 Nm).
    4.  
    5. Step 3: 72 ft. lbs. (100 Nm).
    6.  

  16.  
  17. Install or connect the following:
    NOTE
    Be sure the camshaft sprocket and the crankshaft pulleys are aligned to TDC.



    Intake manifold and tighten the nuts in a crisscross pattern, in 2 or 3 steps, beginning with the inner nuts. Final torque should be 16 ft. lbs. (22 Nm). Always use a new intake manifold gasket.
     
    Intake manifold bracket to the intake manifold: 16 ft. lbs. (22 Nm)
     
    Heat insulator to the cylinder head and the block
     
    Power steering pump mounting bracket to the cylinder head. Tighten the 2 10mm bolts to 36 ft. lbs. (50 Nm). Torque the 8mm bolt to 16 ft. lbs. (22 Nm).
     
    Exhaust manifold and tighten the nuts in a crisscross pattern in 2 or 3 steps, beginning with the inner nut. Final torque should be 23 ft. lbs. (32 Nm). Always use a new exhaust manifold gasket.
     
    Exhaust manifold bracket, then the exhaust pipe, bracket and upper shroud
     



    Timing belt.
     
    Splash shield and the front wheels
     

  18.  
  19. Lower the vehicle.
  20.  
  21. Check and adjust the valves, as necessary.
  22.  
  23. Tighten the crankshaft pulley bolt to 181 ft. lbs. (250 Nm).
  24.  
  25. Installation of the remaining components is the reverse of removal.
  26.  
  27. Fill the cooling system.
  28.  
  29. Connect the negative battery cable and enter the radio security code.
  30.  
  31. Start the engine and check carefully for any leaks.
  32.  
  33. Check the ignition timing and tighten the distributor bolts to 13 ft. lbs. (18 Nm).
  34.  
  35. If equipped with engine and turn the steering wheel lock-to-lock to reset the 4WS control unit.
  36.  

S2000
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Be sure the cylinder head is cool to the touch before beginning the removal procedure. The coolant temperature must be below 100°F (38°C).
  4.  
  5. Relieve the fuel system pressure. Disconnect the negative battery cable. Drain the engine coolant. Drain the engine oil.
  6.  
  7. Remove the air cleaner assembly. Remove the intake air cleaner housing. Remove the drive belt.
  8.  
  9. On 2001-05 vehicles remove the throttle cable, fuel feed hose, fuel return hose and power brake booster hose.
  10.  
  11. On 2006 vehicles, remove the intake manifold cover, power brake booster hose and the quick-connect fitting cover, then disconnect the fuel feed hose.
  12.  
  13. Disconnect the evaporative emission canister hose. Remove the intake manifold bracket retaining bolt. Remove the water outlet cover.
  14.  
  15. Remove the engine wire harness connectors and the wire harness clamps from the cylinder head and intake manifold. Remove the four fuel injector connectors
  16.  
  17. On 2001-05 vehicles, disconnect the IAT sensor connector, heated oxygen sensor connector, throttle position sensor connector, engine coolant temperature sensor connector and the idle air control sensor connector.
  18.  
  19. On 2006 vehicles, disconnect the engine coolant temperature sensor connector, throttle body connector, and the air/fuel sensor connector.
  20.  
  21. Disconnect the manifold absolute pressure connector, rocker arm oil control solenoid connector, rocker arm oil pressure switch connector and the crankshaft position sensor connector.
  22.  
  23. On 2001-05 vehicles, remove the two bolts securing the intake manifold bracket and remove the water bypass hose.
  24.  
  25. 2006 vehicles, remove the water bypass hose, EVAP hose and bracket and the intake manifold bracket.
  26.  
  27. Remove the four bolts retaining the exhaust manifold cover. Remove the heat shield retaining bolts. Remove the heat shield.
  28.  
  29. Remove the exhaust manifold cover. Remove the exhaust manifold retaining bolts and remove the exhaust manifold.
  30.  
  31. On 2001-05 vehicles, remove the injectors.
  32.  
  33. Remove the intake manifold bracket clips. Remove the intake manifold retaining bolts. Remove the intake manifold.
  34.  
  35. Remove the cylinder head cover retaining bolts. Remove the cylinder head cover.
  36.  
  37. Position the No. 1 piston at TDC. The TDC marks on the cam chain sprocket should align with the cylinder head surface.
  38.  
  39. Remove the end cover and nozzle from the cam chain auto tensioner. Thread a nut onto a 5x0.8 mm bolt at is at least 40 mm long. Thread the bolt into the maintenance hole in the cam chain auto tensioner.
  40.  
  41. Turn the bolt clockwise to compress the cam chain auto tensioner and lock it in place with the nut. Remove the cam chain auto tensioner.
  42.  
  43. Loosen the rocker arm adjusting screws. Remove the camshaft holders and camshafts.
  44.  
  45. Insert the bolts into the rocker shaft holder and remove the rocker arm assembly.
  46.  
  47. Remove the idler gear/cam chain sprocket assembly, idler gear collar and washer.
  48.  
  49. Remove the cylinder head retaining bolts. To prevent warpage, loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.0L and 2.2L engines

  50.  
  51. Remove the cylinder head from the engine.
  52.  

To install:


NOTE
Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

  1. Be sure the cylinder head and the engine block surfaces are clean, level, and straight.
  2.  
  3. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil control orifice and reinstall it with a new O-ring.
  4.  
  5. Apply liquid gasket, part number 08717-0004, 08718-0001, 08718-0003 or 08718-0009 to the cylinder head mating surface of the block and chain case within 5mm of the edge of the cylinder head gasket.
    NOTE
    Do not install the parts if more than five minutes have elapsed since applying the liquid gasket. Instead, reapply the liquid gasket after removing the old residue.

  6.  
  7. Position the cylinder head on the engine.
  8.  
  9. Coat the threads of the cylinder head retaining bolts with clean engine oil. Tighten the cylinder head bolts sequentially to the proper torque.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.0L and 2.2L engines

  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. On 2001-05 vehicles, reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  14.  
  15. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 176 degrees.
  16.  
  17. Let the engine idle for about five minutes with the throttle fully closed.
  18.  
  19. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  20.  
  21. On 2006 vehicles, reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  22.  
  23. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  24.  
  25. Stop the vehicle, but keep the engine running.
  26.  
  27. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  28.  
  29. Stop the vehicle, but keep the engine running.
  30.  
  31. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  32.  
  33. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  34.  
  35. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  36.  
  37. Reprogram the power window control unit as follows.
  38.  
  39. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  40.  
  41. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  42.  
  43. Repeat the above step three more times. Wait one second.
  44.  
  45. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  46.  
  47. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  48.  
  49. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  50.  
  51. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  52.  
  53. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  54.  

 
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