2003 HONDA CIVIC ERS

Cylinder Head
Camshaft Inspection (cont'dl
1.
9.
Unscrew the camshaft holder bolts two turns at a
time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
Lift the camshafts out of the cylinder head, wipe
them clean. then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn,
Clean the camshaft journal surfaces in the cylinder
head, then set the camshafts back in place. Place a
plastigage strip across each journal.
Install the camshaft holders, then tighten the bolts
to the specified torque as shown in step 2.
Remove the camshaft holders. Measure the widest
portion of plastigage on each journal.
. lf the camshaft-to-holder clearance is within
limits, go to step 1 1.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has been replaced,
replace the cylinder head.. lf the camshaft-to-holder clearance is beyond the
service limit and the camshaft has not been
replaced, go to step 10.
Camshaft-to-Holder Oil Clearance:
Standard (New):
No. 1 Journal:
No.2,3,4,5 Journals:
Service Limit:
0.030 0.069 mm
{0.001 0.003 in-)
0.060*0.099 mm
{0.002 0.004 in.)
0.15 mm {0.006 in.)
6-30
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10. Check the total runout with the camshaft supported
on V-blocks,
.lfthetotal runout of the camshaft is within the
service limit, replace the cylinder head.. lf the total runout is beyond the service limit,
replace the camshaft and recheck the camshaft-
to-holder oil clearance. lf the oil clearance is still
beyond the service limit, replace the cylinder
neao.
Camshaft Total Runout:
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm {0.002 in.)
11. Measure cam lobe height.
Cam
PRI: Primary
C/C: Cam Chain
SEC: Secondary
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Lobe Heioht Standard (New
INTAKEEXHAUST
PRI33.925 mm(1.3356 in.)
34.092 mm
\1 .3422 in.l
SEC29.638 mm(1.1668 in.)

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

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

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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Cylinder Head Installation
Install the cylinder head in the reverse order of
removat:
1. Clean the cylinder head and block surface.
2. Install the new cylinder head gasket (A) anddowel
pins (B) on the cylinder block. Always use a new
cylinder head gasket.
Set the crankshaft to top dead center {TDC). Align
the TDC mark (A) on the crankshaft sprocket with
the pointer (B) on the cylinder block.
4. Install the cylinder head on the block.
5. Measure the diameter of each cylinder head bolt at
ooint A and Doint B.
a 50 mm (2.0 in.l
f.f )>-
A '15 mm {'1.8 in.)"<>.
lf either diameter is less than 10.6 mm {0.42 in.),
replace the cvlinder head bolt.
(cont d)
6-39

Gylinder Head
Cylinder Head Gover Installation (cont'd)
Set the spark plug seals (A) on the spark plug tubes.
Once the cylinder head cover (B) is on the cylinderhead, slide the cover slightly back and forth to seat
the head cover gasket.
Inspect the cover washers (C). Replace any washer
that is damaged or deteriorated.
6-42
7. Tighten the bolts in two or three steps. In the final
step, tighten all bolts, in sequence, to 9.8 N.m (1.0
kgf.m, 7.2 lbf.ft).
8. Install the dipstick (A) and breather hose iB).
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Component Location Index
MAIN BEARINGSOilclearance, page 7-6Selection, page 7-6
CRANKSHAFTEnd play, page 7-5Runout, page 7-14Out-of-Round, page 7-14Removal, page 7-12lnstallation, page 7-24
fifr"8
-4
E
I
BAFFLE PLATE
LOWER BLOCK
FLYWHEEL
CRANKSHAFT OIL SEAL.TRANSMISSION ENDInstallation, step 21 on page 7-26
THRUST WASHERS
(cont'd)
7-3