2003 HONDA CIVIC exhaust

Valves, Springs, and Valve Seals Installation
Special Tools Required
Valve spring compressor attachment 07VAE-00101 0A
1. Coat the valve stems with engine oil. lnstall the
valves in the valve guides.
2. Check that the valves move up and down smoothly.
Installthe spring seats on the cylinder head.
Install the new valve seals (A) using the valve guide
seal installer (B).
NOTE: The exhaust valve seal (C) has a black spring(D), and the intake valve seal (E) has a white spring(F). They are not interchangeable.
6.
lnstallthe valve spring. Place the end ofthe valve
spring with closely wound coils toward the cylinder
n eao.
Install the valve retainer.
Installthe valve spring compressor, Compress the
spring, and install the valve keepers. Remove the
valve spring compressor.
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 valve keepers. Tap the
valve stem only along its axis so you do not bend
the stem.
7.
6-37

Cylinder Head
Rocker Arm Assembly Installation
:,ean and dry the No. 5 rocker shaft holder mating
surfaces.
eeassemble the rocker arm assembly (see page 6-
21 t.
Apply liquid gasket, P/N 08718-0009, evenly to the
:ylinder head mating surface ofthe No. 5 rocker
shaft holder.
\OTE: Do not lnstall the parts if 5 minutes or more
rave elapsed since applying liquid gasket. Instead,'eapply liquid gasket after removing old residue.
Insert the bolts (A) into the rocker shaft holder, then
install the rocker arm assembly (B) on the cylinder
head.
Apply liquid gasketalong the broken line.
6-38
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5.
6.
Remove the bolts from the rocker shaft holder.
Make sure the DUnch marks on the variable valve
timing control (VTC) actuator and exhaust camshaft
sprocket are facing up. then set the camshafts (A) in
the holder.
Set the camshaft holders (B) and cam chain guide B
(C) in place.
Tighten the bolts to the specified torque.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2 kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
lnstall the cam chain (see page 6-15). and adjust the
valve clearance (see page 6-9).
I
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7.
{

14. Installthe water bvpass hose.
15. Installthe air cleaner housing (see step 37 on page
5-15).
16. Installthe intake manifold (see page 9-5).
17. Installthe exhaust manifold (see page 9-7).
'18. Installthe cam chain (see page 6-15).
19. Adjust the valve clearance (seepage6-9).
20. Installthe drive belt (see page 4-26).
21. Clean the battery posts and cable terminals with
sandpaper, then assemble them and apply grease
to prevent corrosion.
22. After installation, checkthatall tubes, hosesand
connectors are installed correctly.
23. Inspectforfuel leaks. Turn the ignition switch ON
{ll) {do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat thls operation two or three times, then
check for fuel leakage at any point in the fuel line.
24. Refillthe radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
25. Inspect the idle speed (see page 11-'138).
26. Inspect the ignition timing (see page 4-17).
Gylinder Head Cover lnstallation
1. Thoroughly clean the head cover gasket and the
groove.
2. Installthe head cover gasket (A) in the groove of
the cylinder head cover (B).
Check that the mating surfaces are clean and dry.
Apply liquid gasket. P/N 08718-0009, on the chain
case and the No.5 rocker shaft holder mating areas.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
6-41

Engine Mechanical
Intake Manifold and Exhaust System
lntake Manifold Removal and Installation ................. 9-2
Exhaust Manifold Removal and Installation .............. 9-7
Exhaust Pipe and Muffler Replacement ..................... 9-8
r
r-!i!1

Intake Manifold and Exhaust System
lntake Manifold Removal and Installation
Exploded View:
INTAKE MANIFOLD PLATEReplace if cracked orif mating surface isdamaged.
6x1.0mm12 N.m{1.2 kgf.m,8.7 lbf.ft)
\
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GASKETReplace.
8 x 1.2522Nm12.2 ksf
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\8x22
k'e)
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k
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16
.25 mm'mkgf.m, 1
8 x 1.25 mm22 N.m(2.2 kgf m. 16 lbt.ft)
(
8 x 1,25 mm22 N.m {2.2 kgf.m, 16 lbf ft}
INTAKE MANIFOLDReplace if cracked orif mating surface is
9-2
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Intake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'dl
5. Be prepared to catch and clean up spilled coolant.
Remove the water bypass hoses, then plug the
water bypass hoses.
6. Relievefuel pressure (see page 11-'144).
7. Remove the fuel line (seepagell-149).
8. Remove the positive crankcase ventilation (PCV)
hose (A), harness holder mounting bolt (B) and
harness clamp mounting bolt (C).
9-4
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9.Remove the engine wire harness connectors and
wire harness clamps from the intake manifold.
. Four injector connectors. ldle air control (lAC) valve connector. Throttle position (TP) sensor connector. fvlanifold absolute pressure {lvlAP) sensor
connector. Evaporative emission (EVAP)canister purge
valve connector
Remove the bolt securing the intake manifold and
bracket.
'1 0.
11.Remove allthe intake manifold mounting bolts/
nuts.
Remove the two stud bolts (A), then remove the
intake manifold (B).
1'>

lntake Manifold and Exhaust System
Intake Manifold Removal and Installation (cont'd)
9. lnstallthe air cleaner housing cover (A), and
connect the IAT sensor connector (B).
BC
Installthe breather hose (C).
lnstallthe EVAP canister hose (A), brake booster
vacuum hose (B), and vacuum hoses {C).
10.
11.
9-6
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12. Installthe intake manifold cover.
6x1.0mm12 N.ml.1.2k91.m,8.7 tbf.ftl
Clean up any spilled engine coolant.
After installation, check that all tubes, hoses, and
connectors are installed correctly.
Inspect for fuel leaks. Turn the ignition switch ON
(ll) (do not operate the starter) so that the fuel pump
runs for about 2 seconds and pressurizes the fuel
line. Repeat this operation two or three times, then
check for fuel leakage at any point in the fuel line.
Refill the radiator with engine coolant, and bleed
air from the cooling system with the heater valve
open (see page 10-6).
to.
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1.
2.
3.
Exhaust Manifold Removal and Installation
Remove the VTEC solenoid valve (see page 1 '1-128).
Remove the driveshaft heat shield (see page 16-19).
Remove the cover and exhaust manifold bracket, then remove the exhaust manifold.
8x 1.25 mm22 N.m(2.2 kgf.m, 16lbt.ftl
#'-.-
GASKETReplace.
SELF-LOCKING NUT10 x 1.25 mm44 N.m {4.5 ksf.m, 33lbt.ftlBeplace.
10 x 1.25 mm44 N.m(4.5 kgt.m, 33 lbl ftlReplace.
WASHEB8 x 1-25 mm22 N.m (2.2 kgI m, 16lbf.ft)Replace.Tighten the bolts in steps,alternating side to side.10 x 1.25 mm14 N.m{4.5 kgl.rn, 33lbf.ft)
5.
Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning withthe inner bolt.
Installthe other parts in the reverse order of removal.
9-7