Honda Civic Service Manual: Valve, Spring, and Valve Seal Removal and Installation (K24Z7)

1.

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

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 fuel fill cap to relieve the pressure in the fuel tank.

NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.

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.

1.

Turn the ignition switch to ON (II).

2.

From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.

NOTE:

3.

Turn the ignition switch to LOCK (0).

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 bracket (A).

2.

Remove the quick-connect fitting cover (A).

3.

Check the fuel quick-connect fitting for dirt, and clean it if needed.

4.

Place a rag or shop towel over the quick-connect fitting (A).

5.

Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.

NOTE:

1.

Disconnect the intake air duct (A) and the intake air pipe (B).

2.

Remove the harness clamp (C).

3.

Remove the air cleaner (D).

1.

Move the auto-tensioner (A) using the belt tension release tool in the direction of the arrow to relieve tension from the drive belt, then remove the drive belt.

1.

Remove the engine cover.

1.

Remove the intake air duct.

1.

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

2.

Disconnect the connector (A).

3.

Remove the harness clamps (B).

4.

Remove the throttle body without disconnecting the hoses.

1.

Remove the intake manifold bracket.

2.

Remove the intake manifold (A).

3.

Disconnect the PCV hose (A).

1.

Disconnect the connectors.

2.

Move the engine harness holder (A).

1.

Disconnect the quick-connect fitting (A).

2.

Remove the injectors and fuel rail (B) together.

1.

Remove the injector base (A).

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 EVAP canister hose (A) and the brake booster vacuum hose (B).

1.

Remove the rocker arm oil control valve assembly (A) and the rocker arm oil control valve filter (B).

2.

Remove the engine wire harness bracket (C).

1.

Disconnect the connector.

2.

Remove the A/F sensor (A).

1.

Remove the WU-TWC (A).

2.

Remove the WU-TWC cover (B).

1.

Disconnect the upper radiator hose (A) and the heater hoses (B).

1.

Remove the the EVAP canister purge valve bracket (A).

1.

Remove the right front wheel.

1.

Remove the ignition coil cover.

1.

Remove the ignition coils.

1.

Remove the cylinder head cover.

1.

Turn the crankshaft so its white mark (A) lines up with the pointer (B).

NOTE: The other pointer (C) is not used.

1.

Remove the harness clamp.

1.

Remove the ground cable (A).

2.

Remove the VTC oil control solenoid valve (B).

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, then remove the crankshaft pulley.

1.

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

1.

Remove the upper torque rod.

1.

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

1.

Remove the side engine mount bracket.

1.

Remove the cam chain case (A) and the spacer (B).

1.

Loosely install the crankshaft pulley.

2.

Turn the crankshaft counterclockwise to compress the auto-tensioner.

3.

Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. 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.

4.

Remove the auto-tensioner.

1.

Remove cam chain guide B.

2.

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

1.

Remove the cam chain.

1.

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

2.

Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.

3.

Remove cam chain guide B , the camshaft holders (A).

1.

Remove the camshafts (A).

1.

Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

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.

Using an appropriate-sized socket (A) and a plastic mallet (B), lightly tap the spring retainer to loosen the valve cotters.

2.

Install the valve spring compressor attachment and the valve spring compressor. Compress the valve spring, and remove the valve cotters.

3.

Remove the valve spring compressor and the valve spring compressor attachment, then remove the spring retainer, the valve spring and the valve.

1.

Install the valve guide seal remover (A).

2.

Remove the valve seal.

3.

Remove the valve spring seat.

1.

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

2.

Install the valves in the valve guides.

3.

Check that the valves move up and down smoothly.

4.

Install the spring seats on the cylinder head.

5.

Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).

NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white or silver spring (F); they are not interchangeable.

6.

Install the valve spring and the spring retainer. Place the end of the valve spring with the closely wound coils toward the cylinder head.

1.

Install the valve spring compressor attachment and the valve spring compressor. Compress the valve spring, and install the valve cotters.

2.

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

3.

Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and the valve cotters. Tap the valve stem only along its axis so you do not bend the stem.

NOTE: Be sure to raise the head off the work bench so the valve is not possibly damaged.

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.

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

2.

Clean the cylinder head and the engine block surface.

3.

Install the new cylinder head gasket (A) and the dowel pins (B) 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 39 N·m (4.0 kgf·m, 29 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 90 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

1.

Clean and dry the No. 5 rocker shaft holder mating surface.

2.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the cylinder head mating surface of the No. 5 rocker shaft holder and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

3.

Install the lost motion assemblies (A) in the cylinder head.

NOTE: Apply new engine oil to the lost motion assembly.

4.

Insert the bolts (B) into the rocker shaft holder, then install the rocker arm assembly (C) on the cylinder head.

5.

Remove the bolts from the rocker shaft holder.

1.

Make sure the punch marks on the VTC actuator and the exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. Apply new engine oil to the camshaft journals and lobes.

1.

Set the camshaft holders (A) and cam chain guide B in place.

2.

Tighten the bolts to the specified torque.

1.

To hold the intake camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate A and through the No. 5 rocker shaft holder (D).

2.

To hold the exhaust camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate B and through the No. 5 rocker shaft holder (D).

3.

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

4.

Install the cam chain on the VTC actuator and the exhaust camshaft sprocket with the punch marks (A) aligned with the center of the two colored link plates (B).

1.

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

2.

Install cam chain guide B.

1.

Compress the 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 1.2 mm (3/64 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 auto-tensioner.

3.

Remove the pin from the auto-tensioner.

4.

Remove the camshaft lock pin set.

1.

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

2.

Remove the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.

3.

Clean and dry the chain case mating surfaces.

4.

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

5.

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

NOTE:

1.

Install the side engine mount bracket (A), then tighten the side engine mount bracket mounting bolts.

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.

Loosen the transmission mount bracket 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 transmission mount bracket mounting bolt and nuts.

1.

Loosen the lower torque mount mounting bolt.

2.

Tighten the lower torque rod mount mounting bolts in the numbered sequence shown.

1.

Install the upper torque rod using new bolts.

2.

Tighten the upper torque rod mounting bolts in the numbered sequence shown.

1.

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

2.

Install the crankshaft pulley, and hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

3.

Torque the bolt to 50 N·m (5.1 kgf·m, 37 lbf·ft) with a torque wrench and a socket, 19mm(C). Do not use an impact wrench. If the pulley bolt or crankshaft are new, torque the bolt to 177 N·m (18.0 kgf·m, 131 lbf·ft), then remove the bolt and torque it to 50 N·m (5.1 kgf·m, 37 lbf·ft).

4.

Tighten the pulley bolt an additional 90 °.

1.

Install the VTC oil control solenoid valve (A) with a new O-ring (B).

NOTE:

2.

Install the ground cable (C).

1.

Install the harness clamp.

1.

Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

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 with the locknut wrench and the adjuster, and turn the adjusting screw 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 180 ° clockwise (camshaft pulley turns 90 °).

7.

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

8.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

9.

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

10.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

11.

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

1.

Check the spark plug seals for damage. If any seals are damaged, replace them.

2.

Thoroughly clean the head cover gasket and the groove.

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

3.

Install the head cover gasket (A) in the groove of the cylinder head cover (B). Make sure the head cover gasket is seated securely.

4.

Remove all of the old liquid gasket from the chain case and the No.5 rocker shaft holder.

5.

Clean the head cover contacting surfaces with a shop towel.

6.

Apply liquid gasket, (P/N 08718-0004 or 08718-0009) on the chain case and the No. 5 rocker shaft holder mating areas (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

7.

Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.

8.

Inspect the spark plug seals for damage.

9.

Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.

10.

Tighten the bolts in two steps. In the final step torque bolts, in sequence, to 12 N·m (1.2 kgf·m, 9 lbf·ft).

NOTE:

1.

Install the ignition coils.

1.

Install the ignition coil cover.

1.

Install the the EVAP canister purge valve bracket (A).

1.

Connect the upper radiator hose (A) and the heater hoses (B).

1.

Install the WU-TWC cover (A).

2.

Install the WU-TWC (B) with new gaskets (C).

1.

Install the A/F sensor (A).

2.

Connect the connector.

1.

Install the engine wire harness bracket (A).

2.

Install the rocker arm oil control valve assembly (B) and the rocker arm oil control valve filter (C).

1.

Connect the EVAP canister hose (A) and the brake booster vacuum hose (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 injector base (A) with a new gasket (B).

1.

Install the injectors and fuel rail (A) together.

2.

Connect the quick-connect fitting (B).

1.

Install the engine harness holder (A).

2.

Connect the connectors.

1.

Connect the PCV hose (A).

2.

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

3.

Install the intake manifold bracket.

1.

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

2.

Install the harness clamps (A).

3.

Connect the connector (B).

4.

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

1.

Install the intake air duct.

1.

Install the drive belt.

1.

Install the air cleaner (A).

2.

Install the harness clamp (B).

3.

Connect the intake air pipe (C) and the intake air duct (D).

1.

After installation, check that all tubes, hoses, and connectors are installed correctly.

1.

Install the fuel fill cap.

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.

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.

1.

From the INSPECTION MENU of the HDS, select Fuel Pump ON.

NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.

2.

Turn the ignition switch to LOCK (0).

1.

Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.

1.

Install the engine cover.

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.

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

Idle speed should be:

750±50 rpm (in neutral)

2.

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

Idle speed should be:

750±50 rpm (in neutral)

NOTE: If the idle speed is not within specification, do the ECM idle learn procedure. If the idle speed is still not within specification, go to 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 service loop (white tape).

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 cam timing. If the cam timing is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the system works properly, and the ECM was substituted, replace the original ECM.

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..