Honda S2000 Cylinder Head Removal and Installation F20C

Honda S2000 AP1

HONDA S2000 CYLINDER HEAD REMOVAL (F20C)

TIPS:

• Use fender covers to avoid damaging painted surfaces.
• To avoid damage, unplug connectors while holding connector portion.
• To avoid damage to cylinder head, wait until engine temps drops below 100°F (38°C) before loosening the cylinder head bolts.
• Mark wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

1. Make sure you have the anti-theft code for the radio, then write down the
frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery, then disconnect the
positive cable.
3. Drain the engine coolant
4. Drain the engine oil
5. Disconnect the air control solenoid valve connector, then remove the vacuum
hoses and the air cleaner housing/intake air duct assembly.
6. Move the auto-tensioner to remove tension from the alternator-compressor
belt, then remove the alternator-compressor belt.

7. Remove the throttle cable by loosening the locknut, then slipping the cable end
out of the accelerator linkage. Take care not to bend the cable when removing it.
Always replace any kinked cable with a new one. See image.
8. Relieve fuel pressure
9. Remove the fuel feed hose, fuel return hose and brake booster vacuum hose. See image.
10. Remove the evaporative emission (EVAP) canister hose. See image.
11. Remove the bolt securing the intake manifold bracket, and remove the air hose. See image.
12. Remove the water outlet cover. See image.
13. Remove two bolts securing the intake manifold bracket, and remove the
water bypass hose. See image.
14. Remove the engine wire harness connectors and wire harness clamps from
the cylinder head and intake manifold.

• Four fuel injector connectors
• Intake air temperature (IAT) sensor connector
• Idle air control (IAC) valve connector
• Throttle position (TP) sensor connector
• Manifold absolute pressure (MAP) sensor connector
• Engine coolant temperature (ECT) sensor connector
• Primary heated oxygen sensor (primary HO2S) connector
• VTEC solenoid valve connector
• VTEC pressure switch connector
• Crankshaft position (CKP) sensor connector

15. Remove the four bolts securing the exhaust manifold cover. See image.
16. Remove the three bolts, and loosen the bolt, then remove the heat shield.

17. Remove the exhaust manifold cover, then remove the exhaust manifold
bracket (A) and the exhaust manifold (B). See image.
18. Remove the dipstick, positive crankcase ventilation (PCV) hose and
breather hose. See image.
19. Remove the ignition coil cover, then remove the ignition coils. See image.
20. Remove the injectors
21. Remove the intake manifold bracket and the intake manifold. See image.
22. Remove the cylinder head cover. See image.
23. Set the No. 1 piston at top dead center (TDC). The TDC marks on the
cam chain sprocket should align with the cylinder head surface. See image.
24. Remove the end cover and nozzle from the cam chain auto-tensioner. See image.
25. Thread a nut onto a 5 x 0.8 mm bolt that is at least 40 mm long, then
thread the bolt into the maintenance hole in the cam chain auto-tensioner. See image.
26. Turn the bolt clockwise to compress the cam chain auto-tensioner,
and lock the bolt with the nut.
27. Remove the cam chain auto-tensioner. See image.
28. Loosen the rocker arm adjusting screws. See image.
29. Remove the camshaft holders and camshafts.
30. Insert the bolts into the rocker shaft holder, then remove the rocker
arm assembly. See image.
31. Remove the idler gear/cam chain sprocket/ washer assembly. Do not drop
the washer into the chain case. See image.
32. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in
sequence 1/3 turn at a time; repeat the sequence until all the bolts are loose.
33. Remove the cylinder head.

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HONDA S2000 CYLINDER HEAD INSTALLATION (F20C)

1. Measure the diameter of each cylinder head bolt at point A and point B.
If either diameter is less than 11.5 mm (0.45 in.), replace the cylinder head bolt. See image.
2. Clean the cylinder head and block surfaces.
3. Apply liquid gasket, P/N 08718-0009, to the shaded areas of the cylinder
head gasket mating surface of the block and chain case. See image.
4. Install the dowel pins and the new cylinder head gasket. See image.
5. Apply liquid gasket, P/N 08718-0009, to the cylinder head mating surface
of the block and chain case within 5 mm of the edge of the cylinder head gasket. See image.
6. Install the cylinder head on the engine block.
7. Apply new engine oil to the threads and under the heads of all the
cylinder head bolts.
8. Tighten the cylinder head bolts in sequence to 29 N-m (3.0 kgf.m, 22 lbf.ft).
Use a beam-type torque wrench. When using a preset-type torque wrench,
be sure to tighten slowly and do not overtighten. If a bolt makes any noise
while you are torquing it, loosen the bolt and retighten it. See image.
9. Tighten all cylinder head bolts in two steps (90° per step). If you are using
a new cylinder head bolt, tighten the bolt an extra 90°. See image.
10. Tighten the 8 mm bolts to 22 N-m (2.2 kgf.m, 16 lbf.ft).
11. Make sure the crankshaft pulley is at top dead center (TDC). Align the
TDC mark on the crankshaft pulley with the pointer on the chain case. See image.
12. Assemble the idler gear and cam chain sprocket with three mounting bolts.
Torque the bolts to 14 N-m (1.4 kgf.m, 10 lbf.ft). See image.
13. Place the assembly into the cylinder head.
14. Install the cam chain on the sprocket, then fit the assembly into the
cylinder head.
15. Turn the idler gear counterclockwise to relieve cam chain free play, and
check the alignment of the TDC marks on the cam chain sprocket with the
cylinder head surface. If the cam chain sprocket is not positioned at TDC,
remove the idler gear from the cylinder head and reposition the cam chain
to bring the cam chain sprocket to TDC. See image.
16. Apply new engine oil to the idler gear/cam chain sprocket center bolt
threads. Install a new O-ring on the bolt. See image.
17. Install the washer on the cam chain sprocket, and tighten the center bolt.
18. Clamp the cam chain auto-tensioner in a soft-jawed vise.
19. Turn the 5 x 0.8 mm bolt clockwise to compress the bottom of the
auto-tensioner, then insert the set pin, P/N 14511-PCX-005. See image.
20. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new
O-ring, then install the nozzle and end cover. See image.
21. Install the cam chain auto-tensioner in the cylinder head with new O-rings. See image.
22. Remove the maintenance bolt from the cylinder head.
23. Remove the set pin from the cam chain auto-tensioner. Reinstall the
maintenance bolt with a new washer. See image.
24. Install the rocker arm assembly, and check the alignment of the TDC
marks on the cam chain sprocket with the cylinder head surface. See image.
25. Align the TDC marks on the intake camshaft gear and the exhaust
camshaft gear, and install the camshafts.
26.Apply new engine oil to the bolt threads of all the camshaft holder bolts.
27. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 N-m (2.2 kgf.m, 16 lbf.ft). See image.
28. Make sure the camshaft gears are at TDC. See image.
29. Adjust the valve clearance.
30. Install the cylinder head cover.
31. Install the exhaust manifold using new gaskets and new self-locking nuts. See image.
32. Install the exhaust manifold bracket. Make sure the smooth sides of the
washers face the exhaust manifold bracket.
33. Put the exhaust manifold cover on the exhaust manifold.
34. Install the heat shield. See image.
35. Tighten the four bolts securing the exhaust manifold cover. See image.
36. Install the intake manifold with a new gasket. See image.
37. Install the injectors.
38. Install the water bypass hose, and tighten the two bolts securing the
intake manifold bracket. See image.
39. Install the water outlet cover with a new O-ring. See image.
40. Install the air hose, and tighten the bolt securing the intake manifold bracket. See image.
41. Install the evaporative emission (EVAP) control canister hose. See image.
42. Install the brake booster vacuum hose, fuel return hose and fuel feed hose,
using new washers.

• Honda S2000 2000-2003 AP1 model.
• Honda S2000 2004 AP2 model.

43. Install the alternator-compressor belt.
44. Install the air cleaner housing/intake air duct assembly, then install the
vacuum hoses. Connect
the air control solenoid valve connector. See image.
45. Install the throttle cable, then adjust the cable.
46. After installation, check that all tubes, hoses and connectors are installed correctly.
47. After assembly, wait at least 30 minutes before filling the engine with oil.
48. Refill the radiator with engine coolant, and bleed air from the cooling system with the
heater valve open.
49. Clean the battery posts and cable terminals with sandpaper, then assemble them
and apply grease to prevent corrosion.
50. Inspect for fuel leaks. Turn the ignition switch ON (II) (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.
51. Perform the engine control module (ECM or ECU) idle learn
procedure.
52. Inspect the idle speed.
53. Inspect the ignition timing.
54. Enter the anti-theft code for the radio, then enter
the customer's radio station presets.




Honda S2000 AP1

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