Honda Civic Service Manual: Cylinder Head Removal and Installation (R18A9)

This procedure should be done outside in a well-ventilated area or in a properly equipped CNG shop.

This procedure will allow you to safely work on any part of the fuel system downstream of the manual shut-off valve, such as fuel pressure regulator P1 or the fuel injectors.

1.

Close the manual shut-off valve (A).

2.

Start the engine, and let it idle.

3.

After a few minutes, the engine will stall.

4.

Turn the ignition switch to LOCK (0).

1.

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

1.

Remove the right front wheel.

1.

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

2.

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

NOTE:

3.

Disconnect the positive cable (D) from the battery.

1.

Remove the battery setting plate (A) and the battery (B).

1.

Remove the engine cover.

1.

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

1.

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

1.

Remove the intake air pipe.

1.

Disconnect the intake air duct (A).

2.

Remove the air cleaner (B).

3.

Remove the harness clamp (C).

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

1.

Remove the cowl top wiper covers (A).

2.

Remove the wiper arms (B).

1.

Remove the side cowl cover (A).

2.

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

1.

Remove the center cowl cover (A).

2.

Disconnect the windshield washer tube (B).

3.

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

1.

Remove the under cowl panel (A).

1.

Disconnect the fuel feed hose.

1.

Remove the intake air duct.

1.

Remove the throttle body without disconnecting the hoses.

1.

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

2.

Remove the heater hose clamp bracket.

3.

Remove the intake manifold bracket.

4.

Disconnect the connectors (A).

5.

Remove the harness clamps.

6.

Remove the intake manifold assembly.

1.

Disconnect the connectors (A).

2.

Remove the harness holders (B).

3.

Remove the harness clamp (A).

4.

Disconnect the PCV hose from the clamp (B).

5.

Remove the harness holder (A) from the cylinder head.

6.

Disconnect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).

1.

Remove the ignition coils.

1.

Disconnect the connector.

2.

Remove the A/F sensor (A).

1.

Remove the exhaust chamber cover (A).

1.

Remove the engine undercover (A).

1.

Disconnect the connector.

2.

Remove secondary HO2S (A).

1.

Remove exhaust pipe A.

1.

Remove the catalytic converter (A).

2.

Remove the catalytic conveter cover (B).

1.

Disconnect the connectors (A).

2.

Remove the harness clamps (B).

3.

Disconnect the connector (A).

4.

Remove the harness clamp (B).

5.

Remove the harness bracket (A).

6.

Disconnect the lower radiator hose (B), the water bypass hose (C), and the heater hose (D).

1.

Remove the thermostat housing.

1.

Loosen the water pump pulley mounting bolts.

1.

Move the auto-tensioner (A) counterclockwise to relieve tension from the drive belt (B).

2.

Remove the drive belt.

1.

Disconnect the connector and the cable.

2.

Remove the harness connector (A) and the harness clamps (B).

3.

Remove the alternator.

1.

Remove the water pump pulley.

1.

Remove the drive belt auto-tensioner (A).

2.

Check for oil leaks from the drive belt auto-tensioner damper (B) and check for damage to the damper rubber.

1.

Remove the dipstick (A).

2.

Disconnect the breather hose (B).

3.

Remove the cylinder head cover.

1.

Set the No. 1 piston at top dead center (TDC). The ‘‘UP’’ mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

1.

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

2.

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

3.

Remove the crankshaft pulley.

1.

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

1.

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

1.

Disconnect the PCV hose.

2.

Remove the oil pump.

1.

Measure the tensioner rod length between the tensioner body and bottom of the flat surface section on the tensioner rod. If the length is more than the service limit, replace the cam chain.

2.

Loosely install the crankshaft pulley.

3.

Turn the crankshaft counterclockwise to compress the auto-tensioner.

4.

Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B).

5.

Insert a 1.0 mm (1/32 in) diameter pin (C) into the holes.

6.

Turn the crankshaft clockwise to secure the pin.

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

7.

Remove the cam chain auto-tensioner.

8.

Remove the crankshaft pulley.

1.

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

2.

Remove the cam chain.

1.

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

2.

Remove the cylinder head.

1.

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

1.

Clean the cylinder head and the engine block surface.

2.

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

3.

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

4.

Install the cylinder head on the engine block.

5.

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

6.

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

7.

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

8.

Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.

9.

After torquing, tighten all cylinder head bolts in two steps (90 ° per step using the sequence shown in step 8). If you are using a new cylinder head bolt, tighten the bolt an extra 60 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure. Do not loosen it back to the specified angle.

1.

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

2.

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

3.

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

1.

Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.0 mm (1/32 in) diameter pin back into the holes (F).

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

2.

Install the cam chain auto-tensioner.

3.

Remove the pin from the cam chain auto-tensioner.

1.

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

2.

Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.

3.

Clean and dry the oil pump mating surfaces.

4.

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

NOTE:

5.

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

6.

Set the edge of the oil pump (A) on the edge of the oil pan (B) with new O-rings (C).

7.

Install the oil pump on the engine block (D).

8.

Loosely install the dowel bolts (E), then tighten the 8mmbolts (F), the 6 mm bolts (G) and the dowel bolts.

9.

Wipe off the excess liquid gasket on the oil pan and oil pump mating surface.

NOTE:

1.

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

2.

Install the ground cable (D).

1.

Remove the jack and the wood block.

1.

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

1.

Loosen the lower torque rod mounting bolt (A).

1.

Tighten the side engine mount bracket mounting bolt and nut.

1.

Tighten the lower torque rod mounting bolt.

1.

Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D).

2.

Lubricate with new engine oil as shown.

3.

Install the crankshaft pulley (A) onto the crankshaft (B) by aligning the flat sides (C) of the pulley with the flat sides (D) of the inner oil pump gear.

When a new crankshaft or a new pulley bolt is installed

4.

Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), torque the bolt to 180 N·m (18.4 kgf·m, 133 lbf·ft) with a torque wrench and a socket (C), then remove the bolt.

5.

Torque the bolt to 50 N·m (5.1 kgf·m, 37 lbf·ft) with a torque wrench and a socket.

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

6.

Tighten the bolt an additional 82 °.

When the crankshaft or the pulley bolt is reused

7.

Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), then torque the bolt to 70 N·m (7.1 kgf·m, 52 lbf·ft) with a torque wrench and a socket (C).

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

8.

Tighten the bolt an additional 90 °.

1.

Set the No. 1 piston at top dead center (TDC). The ‘‘UP’’ mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

3.

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

4.

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

5.

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

6.

Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

7.

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

8.

Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

9.

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

10.

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

11.

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

1.

Thoroughly clean the head cover gasket and the groove.

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

2.

Install the head cover gasket (A) in the groove of the cylinder head cover (B).

3.

Make sure the head cover gasket is seated securely.

4.

Clean the head cover contacting surfaces with a shop towel.

5.

Remove the old liquid gasket from the top edge matting surfaces of the oil pump (A) and cylinder head (B).

6.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the chain case contact areas. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

7.

Install the cylinder head cover.

8.

Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 10 N·m (1.0 kgf·m, 7 lbf·ft).

NOTE:

9.

Connect the breather hose (A).

10.

Install the dipstick (B).

1.

Install the drive belt auto-tensioner.

1.

Install the water pump pulley.

1.

Install the alternator.

2.

Connect the connector and the cable. Make sure the crimped side of the ring terminal faces away from the alternator when you connect it.

3.

Install the harness connector (A) and the harness clamps (B).

1.

Move the auto-tensioner (A) counterclockwise.

2.

Install the drive belt (B).

1.

Tighten the water pump pulley mounting bolts.

1.

Install the thermostat housing (A), using a new gasket (B) and new O-ring (C).

1.

Connect the lower radiator hose (A), the water bypass hose (B), and the heater hose (C).

2.

Install the harness bracket (D).

3.

Install the harness clamp (A).

4.

Connect the connector (B).

5.

Install the harness clamps (A).

6.

Connect the connectors (B).

1.

Install the catalytic conveter cover (A).

2.

Install the catalytic converter (B) with new gaskets (C).

1.

Install exhaust pipe A. Use new gaskets (B) and new self-locking nuts (C).

1.

Install secondary HO2S (A).

2.

Connect the connector.

1.

Install the engine undercover (A).

1.

Install the exhaust chamber cover (A).

1.

Install the A/F sensor (A).

2.

Connect the connector.

1.

Install the ignition coils.

1.

Connect the upper radiator hose (A), the heater hose (B), and the water bypass hose (C).

2.

Install the harness holder (A) to the cylinder head.

3.

Install the harness clamps (A).

4.

Connect the PCV hose to the clamp (B).

5.

Install the harness holders (A).

6.

Connect the connectors (B).

1.

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

2.

Tighten the bolts/nuts in a crisscross pattern in three steps, beginning with the inner bolt.

3.

Install the connectors (A).

4.

Connect the harness clamps.

5.

Install the intake manifold bracket.

6.

Install the heater hose clamp bracket.

7.

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

1.

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

1.

Install the intake air duct.

1.

Connect the fuel feed hose (A) with a new O-ring (B).

1.

Install the under cowl panel (A).

1.

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

2.

Connect the windshield washer tube (B).

3.

Install the center cowl cover (C).

1.

Install the side cowl cover (A).

2.

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

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

1.

Install the wiper arms (A).

2.

Install the cowl top wiper covers (B).

1.

Install the harness clamp (A).

2.

Install the air cleaner (B).

3.

Connect the intake air duct (C).

1.

Install the intake air pipe.

1.

Install the engine cover.

1.

Install the battery (A) and the battery setting plate (B).

NOTE: Do not deform the battery setting plate by over-tightening the nuts.

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

1.

Clean the battery terminals.

2.

Connect the positive cable (A) to the battery.

NOTE: Always connect the positive side first.

3.

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

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

4.

Apply multipurpose grease to the terminals to prevent corrosion.

1.

Open the manual shut-off valve (A).

Check for a gas leak if there is an odor coming from the vehicle. Compressed natural gas (CNG) can only be smelled, not seen.

1.

Open the hood and the fuel fill door.

2.

Connect a vacuum pump/gauge, 0－30 inHg, to the hose (A) from fuel pressure regulator P1, and apply 67.7 kPa (20.0 inHg, 508 mmHg) of vacuum.

3.

If fuel pressure regulator P2 does not hold vacuum, replace it before continuing to the next step.

4.

Inspect the fuel lines and hoses under the hood for kinks, abrasion, and other signs of damage.

5.

With the manual shut-off valve open, turn the ignition switch to ON (II), but do not start the engine.

6.

After the fuel pressure regulator shut-off solenoid valve/fuel tank internal solenoid valve operates for about 2 seconds, the fuel pressure in the fuel lines rises.

7.

Turn the ignition switch to LOCK (0).

8.

Repeat this two or three times.

9.

Within 1 minute, check for any damaged lines with a leak detector (A) (Snap-on Combustible Gas Leak Detector or Snoop Liquid Leak Detector (B)).

10.

If no damage was noticed during the inspection, turn the ignition switch to ON (II) for 2 seconds, then turn the ignition switch to LOCK (0).

11.

Within 1 minute, check for a leak at the vent hose outlet inside the fuel pipe protector (A).

12.

If you detect a leak, remove the vent hose, and check the fuel lines and fittings at the in-tank solenoid valve and the join block with a leak detector.

13.

If you cannot find the leak, raise the vehicle on a lift, remove the under-floor cover.

14.

Inspect all the fuel lines under the vehicle, visually, and with a leak detector.

15.

If you still cannot find the leak, remove the rear seat, then check all fuel lines and fittings at the fuel tank and the fuel joint block.

1.

Install the right front wheel.

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

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

1.

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

2.

Turn the ignition switch to ON (II).

3.

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

NOTE:

1.

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

Idle speed should be: 670±50 rpm (in P or N)

2.

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

Idle speed should be: 710±50 rpm (in P or N)

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

1.

Select CRANK PATTERN in the ADJUSTMENT MENU with the HDS.

2.

Select CRANK PATTERN CLEAR, and clear the CKP pattern.

3.

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

1.

Jump the SCS line with the HDS.

2.

Connect the timing light to the No. 1 ignition coil harness.

3.

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

4.

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

5.

Disconnect the HDS and the timing light.

1.

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