2003 HONDA CIVIC Head removal

Valve Guide Replacement
Special Tools Required. Valve guide driver, 5.5 mm 07742-0010100. Valve guide reamer, 5.5 mm 07HAH-PJ7o108
1.Inspect valve stem-to-guide clearance (see page 6-
32t.
As illustrated below, use a commercially available
air-impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the special tool
and a conventional hammer.
10.8 mm{0.,|2 in.)
3. Select the proper replacement guides, and chill
lhem in the freezer section of a refriqerator for
about an hour.
4. Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"C). Monitor the temperature
with a cooking thermometer. Do not getthe head
hotterthan 300'F (150"C); excessive heat may
loosen the valve seats.
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7.
Working from the camshaft side. use the driver and
an aar hammerto drive the guide about 2 mm (0.1
in.)towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
Turn lhe head over, and drive the guide out toward
the camshaft side of the head.
lf a valve guide won't move, drill it out with a I mm
(5/16 inch) bit. then try again. Drill guides only in
extreme cases;you could damage the cylinder
head if the guide breaks.
Remove the new guide(s) from the freezer, one at a
time, as vou need them.
(cont'd)
6-33

Engine Block
Crankshaft and Piston Removal
1. Remove the engine assembly (see page 5-2).
2. Remove the transmission (see page 13-4).
3. Remove the oil pan (see page 7-1 1).
4. Remove the oil pump {see page 8-9).
5. Remove the cylinder head (see page 6-23).
6. Remove the baffle plates.
7. Remove the 8 mm bolts.
E
7-12
8. Remove the bearing cap bolts. To prevent warpage,
unscrew the bolts in sequence 1/3 turn at a time:
repeat the sequence until all bolts are loosened.
Remove the lower block and bearings, Keep all
bearings in order.
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Cooling System
Radiator and Fans Replacement
1. Drain the engine coolant (see page 10-6).
2. Remove the front bumper {see page 20,85).
3. Remove the bulkhead.
4. Remove the upper radiator hose and lower radiator hose.
DRAIN PLUG
UPPER BADIATOR HOSE
BAOIATOA FANASSEMBLY
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O.RINGRADIATOR CAP
BADIATOB
LOWERCUSHION
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RADIATOR FANswtTcH24Nm{2.1t kgl m. 17lbl hl
LOWER FADIATORHOSE
RESERVETANK
A/C CONDENSERFAN ASSEMBLY
9.8 N m {1.0 kgf m,7.2 lbf ft)CONNECTORSRADIATOB FAN SWITCHCONNECTOB
5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out.
6. Remove the fan shroud assemblies and other parts from the radiator.
7. Installthe radiator in the reverse order of removal. Make sure the upper and lower cushions are set securelV.
8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts.
9. Fill the radiator with engine coolant and bleed the air (see page 10-6).
10-10
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WC OilControl Solenoid Valve Removal/Test
1. Remove the WC oilcontrol solenoid valve (A).
NOTE: lnstall the valve in the reverse order of
removal with a new o-ring (B), then check these
tlems:
Clean and dry the VTC oil control solenoid valve
mating surface.
Coat the O-ring with engine oil.
Do not install the VTC oilcontrol solenoid valve
while wearing fibrous gloves,
Be careful not to contaminate the cylinder head
openrng.
Check the VTC oil control solenoid valve filter for
clogging. lf it is clogged, replace the VTC oil control
solenoid valve.
Check the clearance between the port (advance
side) and the valve. The clearance (A) should be at
least 2.8 mm (1/8 in.).
Connect the battery positive terminal to VTC oil
control solenoid valve 2P connector terminal No. 2.
VTC OIL CONTROL SOLENOIDVALVE 2P CONNECTOR
Terminal side oJmale terminals
Connect the battery negative terminal to VTC oil
control solenoid valve 2P connector terminal No. 1,
then make sure the valve (A) opens fully.
BATTERY
11-127

VTEC/WC
1.
CMP Sensor A Replacement
Remove the air cleaner (see page 1 1-162).
Disconnect the CMP sensor A 3P connector.
Remove the CMP sensor A (A).
Installthe sensor in the reverse order of removal
with a new o-ring (B).
B-'-----'-l:,",14*
11-128
WEC Solenoid Valve Removal/
Inspection
1.Disconnect the VTEC solenoid valve 2P connector.
Measure resistance between VTEC solenoid valve
connector terminals No. 1 and No. 2.
Resistance: 14-30 Q
3. lf the resistance is within specifications, remove the
VTEC solenoid valve assemblv (A)from the
cylinder head, and check the VTEC solenoid valve
filter (B)for clogging. lf it is clogged, replace the
solenoid valve filter, the engine oilfilter, and the
engine oil.
6x1.0mm9.8 N.m (1.0 kgf.m, 7,2 lbf.ftl
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Steering
Steering Wheel Removal
SRS components are located in this area. Review the
SRS component locations (see page 23-13), and
precautions and procedures (see page 23-14) in the SRS
section before performing repairs or service.
1. Align the front wheels straight ahead, then remove
the driver's airbag from the steering wheel (see
page 23-113).
2. Disconnect the cruise control sevresume switch
connector (A), and loosen the steering wheel nut
{B).
i
17-6
3. Install a commercially available steering wheel
puller {A) on the steering wheel (B). Free the
steering wheel from the steering column shaft by
turning the pressure bolt (C) ofthe puller.
Note these items when removing the steering
wheel:. Do not tap on the steering wheel orthesteering
column shaft when removing the steering wheel.. lf you thread the puller bolts (D) intothewheel
hub more than 5 threads, the bolts will hit the
cable reel and damage it. To prevent this, install
a pair of jam nuts 5 threads up on each puller bolt.
D
Bemove the steering wheel puller, then remove the
steering wheel nut and steering wheel from the
sleerino column.
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EPS Components
Steering Gearbox Removal (cont'd)
Disconnect the EPS wire harness 6P connector (A),
and remove the EPS wire harness (B) and mountino
bracket (C).
12.
Remove the ground cable terminal (A) from the
steering gearbox housing.
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13.
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17-52
14. Remove the engine wire harness clamps {A)fromthe three mounting brackets.
Remove the heater hose {B) from the bracket.
Open the heater valve cable clamp (A), and
disconnect the heater valve cable (B). Remove theheater valve (C) from the bulkhead, and move jt
aside.
t5.
16.
I

Front and Rear Suspension
BallJoint Removal
Special Tools Required
Ball ioint remover.2S mm 07MAC-SL00200
Always use a ball joint remover to disconnect a ball
joint. Do not strike the housing or any other part of
the ball joint connection to disconnect it.
'1, Install a hex nut (A) ontothethreadsoftheballjoint
{B). Make sure the nut is flush with the balljoint pin
end to prevent damage to the threaded end of the
ball ioint oin.
Apply grease to the special tool on the areas shown(A). This will ease installation of the tool and
prevent damage to the pressure bolt {B) threads.
2.
18-10
3. Loosen the pressure bolt (A), and installthe special
tool as shown. Insen the jaws carefully, making
sure not to damage the ball joint boot. Adjust the
jaw spacing by turning the adjusting bolt (B).
10 mm HEX NUT
5.
07MAC-S100200
After adjusting the adjusting bolt, make sure the
head (C) of the adjusting bolt is in the position
shown to allow the jaw to pivot.
With a wrench, tighten the pressure bolt until the
ball ioint pin pops loose from the steering arm or
knuckle. lf necessary. apply penetrating type
lubricant to loosen the ball joint pin
NOTE: Do not use pneumatic or electric tools on
the pressure bolt.
Remove the tool, then remove the nut from the end
ofthe balljoint pin, and pullthe balljoint out ofthe
steering arm or knuckle. Inspectthe balljoint boot,
and replace it if damaged.
6.