2003 HONDA CIVIC valve

Valves, Springs, and Valve Seals Removal
Special Tools Bequired
Valve spring compressor attachment 07VAE-001010A
ldentify the valves and valve springs as they are
removed so that each item can be reinstalled in its
original position.
1. Remove the cylinder head (see page 6-23).
2. Using an appropriate-sized socket (A) and plastic
mallet {B), lightly tap the valve retainer to loosen
the valve keepers.
Install the spring compressor. Compress the spring,
and remove lhe valve keepers.
4. Installthe valve guide seal remover.
5.the valve seal.Remove
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6-31

Gylinder Head
Valve Inspection
1.Remove the valves (see page 6-31),
Measure the valve in these areas.
lntake Valve Dimensions
A Standard lNewl: 34.85 35.15 mm
B Standard {Newl:
C Standard lNew):
C Service Limit:
B Standard (New):
C Standard (New):
C Service Limit:
Exhaust Valve Dimensions
A Standard (New): 29.85-30.15 mm
{1.372 1.384 in.l
108.7 - 109.5 mm
14.280- 4.311 in.)
5.475 5.485 mm
10.2156-0.2159 in.)
5.445 mm {0.214 in.l
(1.175- 1.187 in.)
108.3 109.1 mm
(4.264- 4.295 in.l
5.450 5.460 mm(0.2146 0.2150 in.)
5.42 mm (0.213 in.)
2.
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6-32
t-
Valve Stem-to-Guide Clearance\
Inspection
1.Remove the valves (see page 6-3'1).
Slide the valve out of its guide about 10 mm. then
measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust (wobble method).. lf the measurement exceedsthe service limit,
recheck it using a new valve.. lf the measurement is nowwithin the service
limit, reassemble using a new valve.. lf the measurementwith a newvalve still
exceeds the service limit, go to step 3.
lntake Valve Stem-to-Guide Clearance:
Standard lNew): 0.06 0.11 mm
{0.002 0.004 in.}
Service Limil: 0.16 mm {0.006 in.)
Exhaust Valve Stem-to-Guide Clearance:
Standard lNewl:0.11 -0.16 mm
10.004 0.006 in.)
Service Limit: 0.22 mm 10.009 in.)
Subtract the O.D. of the valve stem. measured with
a micrometer, from the LD. of the valve guide,
measured with an inside micrometer or ball gauge.
Take the measurements in three places along the
valve stem and three places inside the valve guide.
The difference between the largest guide
measurement and the smallest stem measurement
should not exceed the service limit
lntake Valve Stem-to-Guide Clearance:
Standard (New): 0.030 0.055 mm
{0.0012 0.0022 in.)
Service Limit; 0.08 mm (0.003 in.l
Exhaust Valve Stem-to-Guide Clearance:
Standard {Newl: 0.055 0.080 mm(0.0022-0.003r in.l
Service Limit: 0.11 mm (0.004 in.)
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3.
4,.
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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.
-_|Jfillr-.-4fi'11., -
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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

Cylinder Head
Valve Guide Replacement (cont'dl
Apply a thin coat of clean engine oil to the outside
of the new valve guide. Install the guide from the
camshaft side of the head; use the special tool to
drive the guide in to the specified installed height
(A) o{the guide (B). lf you have all 16 guidesto do,
you may have to reheat the head.
Valve Guide Installed Height:
Intake: 15.2 16.2 mm (0.598-0.638 in.)
Exhaust: 15.5 16.5 mm (0.610-0.650 in.)
6-34
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10.Coat both reamer and valve guide with cutting oil.
Rotate the reamer clockwise the full length of the
valve guide bore.
O7HAH.PJ7O1OB
Continue to rotate the reamer clockwise while
removing it from the bore.
Thoroughly wash the guide in detergent and water
to remove any cutting residue.
Check the clearances with a valve (see page 6 32).
Verify that a valve slides in the intake and exhaust
valve guides without exening pressure.
11.
14.
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Valve Seat Reconditioning
1. Inspect valve stem-to-guide clearance (see page 6-
32). lf the valve guides are worn, replace them (see
page 6-33) before cutting the valve seats.
2. Renew the valve seats in the cylinder head using a
valve seat cutter.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper and lower edges at the angles
shown in the illustration.
Check the width of the seat and adjust accordingly.
INTAKE:35"EXHAUST:30'
3,
4.
- 45'
, { 67.5'
5. Make one more very light pass with the 45" cutter
to remove any possible burrs caused by the other
cutters.
Valve Seat Width:
Standard (New): 1.25 1.55 mm {0.049 0.061 in.)
Service Limit: 2.00 mm (0.079 in.)
6. After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue compound (A) to the
valve face. Insert the valve in its original location in
the head, then lift it and snap it closed against the
seat several trmes.
1.The actual valve seating surface (B), as shown by
the blue compound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 67.5' cutter to
move it down, then one more cut with the 45"
cutter to restore seat width.. lf it is too low (close to the valve edge), you must
make a second cut with the 35'cutter (intake
sidel or the 30" cutter (exhaust side) to move it up,
then make one more cut with the 45" cutter to
restore seat width.
NOTE: The final cut should always be made with
the 45'cutter.
(cont'd)
6-35

Cylinder Head
8.
Valve Seat Reconditioning (cont'dl
Insen the intake and exhaust valves in the head,
and measure valve stem installed height (A).
Intake Valve Stem Installed Height:
Standard {New):40.8 41.0 mm(1.606 1.614 in.)
Exhaust Valve Stem Installed Height:
Standard (New): 54.6-54.8 mm
|'2.150 -2.157 in.l
lf valve stem installed height is over the standard,
replace the valve and recheck. lf it is still over the
standard, replace the cylinder head; the valve seat
in the head is too deeD.
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6-36
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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).
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7.
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