Contents: Removal ⇊ Installation ⇊
Removal
1. Disconnect the battery from ground.
2. Remove the cylinder head cover and upper camshaft belt cover.
3. Set the piston of the 1st cylinder to TDC of the compression stroke by turning the crankshaft until the marks align.
4. Drain the coolant.
5. Drain the oil from the engine.
6. Disconnect the throttle and cruise control cables (if provided). Deformation or excessive bending of the cable during removal is not allowed
7. Remove the air duct and air filter.
8. Mark and disconnect the crankcase ventilation and recirculation system hoses.
9. Decompress the fuel system.
10. Disconnect the fuel lines at the pressure regulator.
11. Disconnect the vacuum hoses near the fuel return line.
12. Disconnect all vacuum hoses from the manifold.
13. Remove the power steering hose from the suspension cap.
14. Disconnect the ground bus from the manifold.
15. Remove all wiring harnesses from the cylinder head cover.
16. Remove the power steering pump drive belt.
17. Disconnect the wires from the intake manifold at its bottom.
18. Label and disconnect the engine wiring connectors (including connectors for injectors, sensors, idle air valve, ignition coil)
19. Disconnect the wires from the ignition distributor. Remove the ignition distributor.
20. Disconnect the radiator and heater hoses from the cylinder head.
21. Place a jack under the engine and lift the engine slightly. Remove the through bolt and remove the side engine mount.
22. Remove the cylinder head cover.
23. Remove the camshaft belt, having first removed the covers.
24. Remove the rear camshaft belt cover and camshaft sprocket.
25. Raise the vehicle, disconnect the front exhaust pipe from the manifold and lower the vehicle.
26. Remove the exhaust manifold and shield.
27. Remove the thermostat housing by unscrewing the bolts and turning the housing.
28. Remove the fuel distributor and injectors.
29. Loosen the bolts and remove the equalizing chamber with the throttle pipe.
30. Remove the intake manifold.
31. Loosen the cylinder head bolts in a diagonal sequence, starting from the periphery and moving towards the center, making 1/3 of a turn at a time. Remove the cylinder head.
Installation
32. Clean the head and the parting surface of the cylinder block. Check the deformation of the planes, which should not exceed 0.15 mm. If the deformation exceeds 0.15 mm, grind the head. When grinding, it is permissible to reduce the head height by no more than 0.20 mm (base head height 100 mm).
33. Install the new head gasket.
34. Make sure that the piston of the 1st cylinder is set to TDC.
35. Clean the oil nozzle and install, replacing the seal. Install new control pins.
36. Tighten the intake manifold mounting bolts to the bracket without tightening.
37. Install the camshaft so that the UP mark faces upward.
38. Install the cylinder head, making sure that the pins enter the holes in the head. On 1996-97 engines, lubricate the bolts and tighten by hand. Tighten the bolts in the following order.
Tighten the bolts in a diagonal pattern in three stages: tighten the bolts to 39 Nm, then tighten to 69 Nm. And finally tighten to 98.1 Nm.
On 1998 engines, lubricate the bolts and tighten in the following order.
- Step 1 - Tighten the bolts to 39 Nm,
- Step 2 - Apply marks to the bolt heads and cylinder head surface as shown in the photo,
- Step 3 - tighten the bolts by 90° relative to the marks on the cylinder head,
- Stage 4 - tighten the bolts another 90°, tighten the new bolts another 90° relative to the position at stage 4 of tightening.
39. Install the intake manifold, equalizing chamber and throttle pipe.
40. Install the injectors on the pressure regulator, install the regulator on the intake manifold, replacing all gaskets and seals.
41. Install the exhaust manifold by raising the vehicle.
Markings on the cylinder head bolts, according to which additional tightening is performed: 1. Bolt head; 2. Cylinder head
42. Install the rear camshaft belt cover. Install the key and sprocket onto the camshaft and tighten the sprocket bolt to 37 Nm.
43. Make sure that the UP mark on the camshaft sprocket is facing up and the orientation of the crankshaft and camshaft pulleys corresponds to the position of the piston of the 1st cylinder at TDC of the compression stroke.
44. Install the camshaft and balance shaft belts.
45. Install the lower camshaft belt cover and tighten the bolts to 12 Nm.
46. Install a new seal around the adjusting nut. Do not loosen the nut.
47. Install the crankshaft pulley and tighten the bolt to 245 Nm.
48. Install the side engine support. Tighten the engine mounting bolts to a torque of 55 Nm, tighten the nut of the through support bolt to a torque of 65 Nm.
49. Adjust the valve clearances.
50. Install the upper camshaft belt cover. Tighten the bolt on the intake manifold side to a torque of 12 Nm, and on the exhaust manifold side to a torque of 10 Nm.
51. After adjusting the valves, check the tightening of the crankshaft pulley bolt; if necessary, tighten to a torque of 245 Nm.
52. Install the cylinder head cover, tighten the cover nuts clockwise to a torque of 10 Nm.
53. Install the thermostat housing, replacing the gasket. Connect the cooling system bypass hoses.
54. Further assembly is carried out in the reverse order of disassembly. Connect hoses, wires and cables. Adjust the belt tension. Adjust the throttle and cruise control cables. Fill the engine with oil and fluid. When finished, start the engine, check the ignition timing, adjust if necessary.
(The original is located on the website: Hondabook.ru)