Repair Procedure

How to use this manual .

Courtesy of HONDA, U.S.A., INC.

: Torque, N.m (lbf.ft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

■: SPL Tool

: Required Removal

Courtesy of HONDA, U.S.A., INC.

: Torque, N.m (lbf.ft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

■: SPL Tool

: Required Removal

A.-

Key Information

Do the following before starting your work.

Remove:

Drive Belt - Refer to: Alternator Area(2.0L Engine)

Sub-Procedure

NOTE:

Do not use an impact wrench.

Figure 1

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Removal

Refer to the Figure 1.

Figure 2

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Installation

1. Refer to the Figure 2.

a: Clean

Lubricant Specifications (Figure 2)

Position	Type
b	Engine Oil

Figure 3

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2. Refer to the Figure 3.

Tightening Procedure (When a new crankshaft and/or a new pulley bolt is installed) (Figure 3)

Step	Operation	Specification
1	Temporarily Tighten	180 N.m (133 lbf.ft)
2	Remove	-
3	Temporarily Tighten	50 N.m (37 lbf.ft)
4	Angle Tighten	c	90 deg.

Tightening Procedure (When the crankshaft and the pulley bolt is reused) (Figure 3)

Step	Operation	Specification
1	Temporarily Tighten	50 N.m (37 lbf.ft)

Step.	Operation	Specification
2	Angle Tighten	c	90 deg.

B.-

Sub-Procedure

Removal

NOTE:

Be careful not to damage the crankshaft and the cam chain case.

Figure 1

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Figure 2

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Installation

1. Clean and dry the oil seal housing.

Lubricant Specifications

Position	Type
a	Engine Oil

Installation Depth

Standard Value
b	5.6-5.9 mm (0.220-0.232 in)

2. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.

C.-

Key Information

Do the following before starting your work.

Remove:

Right Front Wheel - Refer to: Front Brake Area(2.0L Engine)
Right Front Inner Fender (as needed)

Sub-Procedure

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Installation

Remove all of the old gasket from the mating surfaces of each part and clean it.

Lubricant Specifications

Position	Type	Detail
a	Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718- 0009)	b	2.5 mm (0.098 in)

NOTE:

Install the component within 5 minutes of applying the liquid gasket.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the parts.

D.-

Sub-Procedure

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Installation

Clean and dry the mating surface of the valve (a).

Lubricant Specifications

Position	Type
b	Engine Oil

E.-

Sub-Procedure

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Installation

Remove any old liquid gasket from the oil pressure switch and the switch mounting hole.

Lubricant Specifications

Position	Type
a	Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718- 0009)

NOTE:

Install the component within 5 minutes of applying the liquid gasket.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the parts.

F.-

Preconditions

Engine Oil Drained - Refer to: Engine Oil Level Check or Engine Oil Replacement(2.0L Engine)

Key Information

Do the following before starting your work.

Remove:

Cylinder Head Cover - Refer to: Cylinder Head Cover Area(2.0L Engine)
Alternator Area Parts - Refer to: Alternator Area(2.0L Engine)
- Drive Belt Auto-Tensioner
- Drive Belt Idler Pulley (If necessary)
Turbocharger Bypass Control Valve Solenoid Pipe B Mounting Bolt - Refer to: Water Pump Area(2.0L Engine)

Procedure:

Coolant Reservoir Move (If necessary) - Refer to: Radiator Area(2.0L Engine)

Sub-Procedure

Installation

1. Check the pulley end crankshaft oil seal for damage. If the oil seal is damaged, replace the pulley end crankshaft oil seal.

2. Remove all of the old gasket from the mating surfaces of each part and clean it.

Lubricant Specifications (Figure 1)

Position	Type	Detail
a	Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718- 0009)	f	2.5 mm (0.098 in)
b		g	3.5 mm (0.138 in)
c		h	5.0 mm (0.197 in)
d		i	5.0 mm (0.197 in)
d		k	11 mm (0.43 in)
e		m	2.5 mm (0.098 in)
e		n	11 mm (0.43 in)

Lubricant Specifications (Figure 1)

Range
o	31 mm (1.22 in)
p	45 mm (1.77 in)
q	29.5 mm (1.161 in)
r	5.0 mm (0.197 in)
s	7.0 mm (0.276 in)

NOTE:

Install the component within 5 minutes of applying the liquid gasket.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the parts.

Figure 1

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3. Install the cam chain case as shown. Wipe off the excess liquid gasket on the oil pan and the cam chain case mating area. (Figure 2)

NOTE:

When installing the cam chain case, do not slide the bottom surface onto the oil pan mounting surface.

Figure 2

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G.-
Sub-Procedure

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Installation
- Do the mount tightening procedure - Refer to: Engine Mount Tightening Procedure(2.0L Engine) before tightening all of the mount bolts and nuts.
Installation Direction

Mark Direction

a UP
H.-
Key Information

Do the following before starting your work.

Remove:
- Engine Undercover Plate
Sub-Procedure

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Removal/Installation
- Lift and support the engine with a jack and a wood block under the oil pan.
NOTE:
Do not remove the bolt (a).

Installation
- Do the mount tightening procedure - Refer to: Engine Mount Tightening Procedure(2.0L Engine) before tightening all of the mount bolts and nuts.
I.-
Sub-Procedure

Figure 1

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Removal

NOTE: The cam chain case is no need to remove, when removing only the cam chain auto-tensioner.

1. Loosely install the crankshaft pulley. (After removing the cam chain case)2. Turn the crankshaft counterclockwise to compress the cam chain auto-tensioner. (Figure 1)

Figure 2

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Figure 3

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3. Rotate the crankshaft counterclockwise to align the holes on the lock (a) and the am chain auto-tensioner (b). (Figure 2)4. Insert a pin (c) into the holes. (Figure 2)

NOTE:
If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.

Pin Specifications (Figure 3)

Standard Value

c 1.2 mm (3/64 in)

5. Turn the crankshaft clockwise to secure the pin.

Figure 4

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Installation

When replacing the cam chain or the pin is removed
- Slightly compress the cam chain auto-tensioner rod (d) and remove the pin (e) that was installed during the removal of the tensioner. Turn the plate (f) counterclockwise to release the lock, then compress the rod and set the cam (g) to the first notch (h). Reinsert the pin into hole (i) to lock it in place. (Figure 4)
NOTE:
If the cam chain auto-tensioner is not set up as described, the cam chain auto-tensioner will be damaged.
J.-
Sub-Procedure

NOTICE:

NOTE:
Check the cam chain auto-tensioner filter for damage. If the filter is damaged, replace it.

Mark	Direction
a	UP

Standard Value
c	1.2 mm (3/64 in)

K.-

Sub-Procedure

Figure 1

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Removal

1. Install the engine support hanger - Refer to: Engine Support Hanger Installation(2.0L Engine) .)

2. Remove the oil pan - Refer to: A/C Compressor/Engine Oil Pan Area(2.0L Engine)

3. Loosely install the crankshaft pulley. (Figure 1)4. To hold the front balancer shaft, insert a 6 mm long pin punch (a) (Snap-on PPC108LA or equivalent) into the maintenance hole in the balancer shaft holder and through the front balancer shaft. (Figure 1

Tool Details (Figure 1)

Name
a	6 mm Long Pin Punch(Snap-on PPC108LA or equivalent)

5. Turn the crankshaft counterclockwise to compress the oil pump chain. (Figure 1)

6. Remove the crankshaft pulley.

Figure 2

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Figure 3

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7. Align the holes on the lock (b) and the oil pump chain auto-tensioner (c), then insert a pin (d) into the holes. Turn the crankshaft clockwise to secure the pin. (Figure 2)

Pin Specifications (Figure 3)

Standard Value
d	1.5 mm (1/16 in)

Figure 4

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Installation

When replacing the oil pump chain or the pin is removed

Slightly compress the oil pump chain auto-tensioner rod (e) and remove the pin (f) that was installed during the removal of the tensioner. Turn the plate (g) counterclockwise to release the lock, then compress the rod and set the cam (h) to the first notch (i). Reinsert the pin into hole (k) to lock it in place. (Figure 4)

NOTE:

If the oil pump chain auto-tensioner is not set up as described, the oil pump chain auto-tensioner will be damaged.

L.-

Key Information

NOTE: For the removal and installation procedure, refer to Cam Chain Removal and Installation - Refer to: Cam Chain Inspection(2.0L Engine) or Cam Chain Removal and Installation(2.0L Engine) and the sub-procedure below.

Sub-Procedure

NOTE:

Keep the cam chain away from magnetic fields.

Figure 1

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Removal

1. Refer to the Figure 1, align the marks.

Assembly Position Details (Figure 1)

Position	Object
a	TDC Mark (VTC Actuator A)
b	TDC Mark (VTC Actuator B)
c	"UP" Mark (VTC Actuator B)
d	TDC Mark (VTC Actuator B)
e	Top Edge of the Cam Chain Case
f	TDC Mark (Crankshaft Sprocket)
g	Pointer (Engine Block)

Figure 2

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Installation

1. Refer to the Figure 2, align the marks.

Assembly Position Details (Figure 2)

Position	Object
h	TDC Mark (VTC Actuator A)
i	TDC Mark (VTC Actuator B)
k	"UP" Mark (VTC Actuator B)
m	TDC Mark (VTC Actuator B)
n	Top Edge of the Cam Chain Case
o	TDC Mark (Crankshaft Sprocket)

Position	Object
p	Pointer (Engine Block)

Figure 3

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2. Insert the camshaft lock pin set. (Figure 3)

Figure 4

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3. Refer to the Figure 4, align the marks and install the cam chain.

Assembly Position Details (Figure 4)

Position	Object
q	Colored Link Plates (Cam Chain)
r	Punch Mark (VTC Actuator A)
s	Colored Link Plates (Cam Chain)
t	Punch Mark (VTC Actuator B)
u	Colored Link Plate (Cam Chain)

Position	Object
v	Mark (Crankshaft Sprocket)

After Installation

NOTE: Do not forget to remove the camshaft lock pin set.

Ignition Timing Inspection - Refer to: or Ignition Timing Inspection(2.0L Engine)

M.-

Preconditions

Set the No. 1 piston at top dead center (TDC).

Sub-Procedure

Figure 1

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Removal

1. To hold the front balancer shaft, insert a 6 mm long pin punch (a) (Snap-on PPC108LA or equivalent) into the maintenance hole in the balancer shaft holder and through the front balancer shaft, then loosen the bolt (b). (Figure 1)

Tool Details (Figure 1)

Name
a	6 mm Long Pin Punch(Snap-on PPC108LA or equivalent)

Figure 2

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2. Remove the oil pump chain with the oil pump sprocket. (Figure 2)

Figure 3

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installation

1. Refer to the Figure 3, align the marks.

Assembly Position Details (Figure 3)

Position	Object
c	TDC Mark (Crankshaft Sprocket)
d	Pointer (Engine Block)

Figure 4

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2. Install the oil pump chain with the oil pump sprocket.

Assembly Position Details (Figure 4)

Position	Object
e	Oil Pump Sprocket
f	Oil Pump Cover

NOTE: These colored link plates (g) shall be used in product process only and not used for maintenance purpose. There is no need to adjust the colored link plates to the markings on the sprockets as they have no effect on the engine operation. (Figure 4)

Figure 5

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3. To hold the front balancer shaft, insert a 6 mm long pin punch (h) (Snap-on PPC108LA or equivalent) into the maintenance hole in the balancer shaft holder and through the front balancer shaft, then tighten the bolt (i) to the specified torque. (Figure 5)

Tool Details (Figure 5)

Name
h	6 mm Long Pin Punch(Snap-on PPC108LA or equivalent)