2003 HONDA CIVIC Workshop Manual

Gylinder Head
Cam Chain Installation (cont'd)
'15. Install the new O-ring (A) on the chain case. Set the
edge of the chain case (B) to the edge of the oil pan(C), then install the chain case on the cvlinder block(D).
NOTE: When installing the chain case, do not slide
the bottom surface on the oil pan mounting surface.
',.9
6x1.0mm12 N.m(1.2 kgt.m.8.7 lbf.ft)
6x1.0mm12Nm(1.2 kgf.m,8.7 lbf.ft)
6-18
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16. lnstallthe side engine mount.bracket.
17. Installthe upper bracket (A), then tighten the bolv
nuts in the numbered seouence shown.
6x1.0 mm12 N.m{1.2 kgl m, 8.7 lbf ft}
12x1.25 mm54 N.m(5.5 kgt m, 40 lbf.ft)
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18. Install the ground cable (B).
rbf.ft)

19.
20.
lnstall the variable valve timing control (VTC) oil
control solenoid valve (see step 1 on page 11'127).
Connect the crankshaft position (CKP) sensor
connector {A) and VTC oil control solenoid valve
connector (B).
21. Install the crankshaft pulley (see page 6-12).
22. Installthe cylinder head cover (see page 6-41).
23. Installthe drive belt.
24. Installthe splash shield.
€D@
Auto-Tensioner RemovaU
lnstallation
Removal:
1. Remove the chain case cover.
Turn the crankshaft counterclockwise to compress
the auto-tensroner.
{cont'd)
6-19

Gylinder Head
Auto-Tensioner Removal/l nstallation
3. Align the holes on the lock (A) and the auto-
tensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the crankshaft
clockwise to secure the oin.
4. Remove the auto-tensioner.
6-20
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(cont'dl
Installation:
1. Install the auto-tensioner.
\
6x1.0mm12 N.m {1.2 kgt.m, 8.7 lbt.tt)
Remove the pin from the auto-tensioner.
a\

Remove old liquid gasket from the chain case cover
mating surfaces, bolts, and bolt holes.
Clean and dry the chain case cover mating surfaces.
Apply liquid gasket, P/N 08718-0009, evenly to the
chain case mating surface of the chain case cover
and to the inner threads of the holes.
NOTE: Do not installthe parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
6. Installthe chain case cover.
4.
6x1.0mm12 N.m{1.2 kgt.m,8.7 tbf.ft)
Apply liquid gasketalong the broken line.
Chain Case Oil Seal Installation
SpecialTools Required. Driver 07749-0010000. Attachment, 52 x 55 mm 07746-0010400
1. Use the special tools to drive a new ollseal
squarely into the chain case to the specified
installed height.
07749-0010000
2. Measure the distance between the chain case
surface (A) and oilseal 1B).
Oil Seal Installed Height:
33.0-33.7 mm (1.30- 1.33 in.)
33.0 33.7 mm{1.30 1.33 in.l
6-21

Gylinder Head
Cylinder Head Cover Removal
1. Remove the intake manifold cover.
2. Remove the four ignition coils (see page 4-'18).
3. Remove the dipstick (A) and breather hose (B).
6-22
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4, Remove the cylinder head cover
V:t :;t 1
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Gylinder Head Removal
NOTE:. Use fender covers to avoid damaging painted
surfaces.
To avoid damage, unplug the wiring connectors
carefully whlle holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100'F (38"C)
betore loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection.
Also, be sure that they do not contact other wiring or
hoses, or interfere with other parts.
'1.
2.
3.
Drain the engine coolant (see page 10-6).
Remove the drive belt (see page 4-26).
Remove the intake manifold {see page 9-3).
Remove the air cleaner housing (see step 7 on page
5-2t.
5. Remove the water bypass hose (A).
Remove the exhaust manifold (see page 9-7
Remove the cam chain (see page 6-12).
6.
7.
).
8. Remove the engine wire harness connectors and
wire harness clamps from the cylinder head.
. Engine coolant temperature (ECT) sensor
conneclor. Camshaft position (Cl\4P) (top dead center (TDC))
sensor B connector. Camshaft posilion (CMP) sensor A connector
9. Remove the upper radiator hose (A) and heater
hose (B).
'10. Remove the harness holder (A)from the bracket,
then remove the connecting pipe mounting boh {B)
and brake booster vacuum line mounting bolts {C).
(cont'd)
1 1. Remove the water bvpass hose (D).
6-23

Cylinder Head
tJ.
Cylinder Head Removal (cont'd)
Remove the rocker arm assembly (see page 6-26).
Remove the cylinder head bolts. To prevent
warpage, unscrew the bolts in sequence 1/3 turn at
a time; repeat the sequence until all bolts are
loosened.
CYLINDER HEAD BOLTS LOOSENING SEQUENGE:
14. Remove the cylinder head.
6-24
VTC Actuator, Exhaust Camshaft\
Sprocket Replacement
Removal:
1. Remove the cam chain (see page 6-12).
2. Hold the camshaft with an open-end wrench, then
loosen the variable valve timing control (VTC)
actuator mounting bolt and exhaust camshaft
sprocket mounting bolt.
Remove the VTC actuator and exhaust camshaft
sprocket.
I\(
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Installation:
1. Install the VTC actuator and exhaust camshaft
sprocket.
2. Apply engine oil to the th reads of the VTC actuato r
mounting bolt and exhaust camshaft mounting bolt,
then install them.
3. Hold the camshaft with an open-end wrench, then
tighten the bolts.
Specified torque:
VTC actuator mounting bolt:
113 N.m (11.5 kgl.m,83 lbl.ft)
Exhaust camshaft sprocket mounting bolt:
72 N m (7.3 kgf.m, 53 lbf.ft)
4. Install the cam chain {see page 6-15).
1,
Cylinder Head Inspection for
Warpage
Remove the cylinder head {see page 6-23).
Inspect the camshaft (see page 6-29).
Check the cylinder head for warpage. Measure
along the edges, and three ways across the center.
. lf warpage is less than 0.05 mm (0.002 in.)
cylinder head resurfacing is not required.. lf warpage is between 0.05 mm (0.002 in.) and
0.2 mm (0.008 in.), resurface the cylinder head.. Maximum resurface limit is 0.2 mm (0.008 in,)
based on a height of 104 mm (4.09 in.).
Cylinder Head Height;
Standard {New}: 103.95 104.05 mm
{4.093 4.096 in.}
6-25