Valve Job - Complete

Complete valve job including removal of cylinder head, valve grinding/replacement, seat machining, and reassembly with new seals and gaskets to restore compression and eliminate valve sealing issues.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use Honda OEM head gasket
• Valve cover gasket × 1 — Use Honda OEM valve cover gasket
• Valve stem seals (set of 16) × 1 — Use OEM specification
• Intake valves (if worn beyond spec) × 8 — Use OEM specification
• Exhaust valves (if worn beyond spec) × 8 — Use OEM specification
• Timing chain tensioner gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Turbo to manifold gasket × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 10 — Use Honda OEM - Replace all
• Spark plugs × 4 — NGK or Denso OEM equivalent
• Anti-seize compound × 1 — Copper or nickel based
• RTV silicone gasket maker × 1 — Honda Bond or equivalent

Fluids

• Honda Genuine 0W-20 — 4 qt
• Honda Type 2 Coolant (Blue) — 6 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and allow engine to cool completely (minimum 2 hours)
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Remove engine cover by pulling up on four corners
4. Drain engine coolant into appropriate container by opening radiator drain and removing upper radiator hose
5. Drain engine oil completely and remove oil filter
6. Remove air intake system from air box to turbocharger inlet
7. Label and photograph all vacuum lines, electrical connectors, and hose routing for reassembly reference
8. Support engine from above using engine support bar or from below with floor jack and wood block on oil pan

Procedure

1. 1

   Remove accessory components and turbocharger
   Disconnect intercooler piping from turbocharger. Remove turbocharger heat shield. Disconnect oil feed line from top of turbo and oil return line from bottom. Disconnect exhaust downpipe from turbo outlet. Remove turbo-to-exhaust manifold nuts and remove turbocharger assembly. Disconnect all ignition coil connectors, remove coil hold-down bolts, and extract ignition coils from valve cover.
2. 2

   Remove valve cover and upper timing components
   Remove PCV hose and breather hoses from valve cover. Remove valve cover bolts in reverse of tightening sequence (outside to inside). Carefully separate valve cover from cylinder head. Remove upper timing chain cover bolts. Note position of any different length bolts for reassembly.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
3. 3

   Position engine at TDC and secure timing chain
   Rotate crankshaft clockwise using 19mm socket on crankshaft pulley bolt until camshaft lobes for cylinder 1 point upward and timing marks align. Install timing chain holding tool or secure chain to camshaft sprockets with wire ties to maintain position. Mark chain-to-sprocket relationship with paint pen on both intake and exhaust cam sprockets.
4. 4

   Remove camshafts
   Hold exhaust camshaft with wrench on hex section and remove camshaft sprocket bolt. Remove exhaust cam sprocket. Repeat for intake camshaft. Remove timing chain tensioner bolt and extract tensioner. Loosen camshaft cap bolts in reverse sequence (outside to inside) in multiple passes, no more than 1/4 turn per pass. Remove camshaft caps keeping them in order. Lift out exhaust camshaft first, then intake camshaft. Store camshafts in protective location.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
5. 5

   Remove rocker arms and intake/exhaust manifolds
   Remove all rocker arm assemblies and store in order. Disconnect fuel rail with injectors and move aside (do not disconnect fuel lines). Remove intake manifold bolts and remove intake manifold with gasket. Apply penetrating oil to exhaust manifold studs. Remove exhaust manifold nuts working from hot side (center) toward cold ends. Remove exhaust manifold and gasket.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Remove cylinder head
   Disconnect remaining coolant hoses from cylinder head. Disconnect all electrical connectors from head-mounted sensors. Remove cylinder head bolts in reverse of tightening sequence (outside to inside) in multiple passes. Carefully lift cylinder head off block using lifting eyes or by hand. Do not pry between head and block surfaces. Place head on clean workbench or cylinder head stand.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
7. 7

   Disassemble valvetrain and inspect components
   Using valve spring compressor, compress each valve spring and remove keepers. Release spring pressure and remove retainer, spring, and valve stem seal. Extract valve from combustion chamber side. Keep all valves in order by cylinder and intake/exhaust position. Clean all carbon deposits from valves, combustion chambers, and ports using appropriate solvent and brushes. Inspect valve stems for wear, scoring, or bent stems. Measure valve stem diameter with micrometer - intake should be 4.975-4.990mm, exhaust 4.965-4.980mm. Check cylinder head surface flatness with straight edge and feeler gauge - maximum allowable warpage is 0.05mm. If warpage exceeds spec, head must be resurfaced.
8. 8

   Machine valve seats and grind valves
   Inspect valve seats for pitting, burning, or damage. Using valve seat cutter set or send to machine shop, cut intake valve seats to 45-degree angle with seat width of 1.0-1.3mm. Cut exhaust seats to same specifications. Grind or lap valve faces to 45 degrees ensuring smooth, even surface. Apply Prussian blue to valve face, insert into guide, rotate valve 1/4 turn under light pressure, and check contact pattern. Contact should be centered on valve face in continuous band. Repeat lapping if pattern is uneven. Clean all grinding compound thoroughly with solvent.
9. 9

   Install new valve stem seals and reassemble valves
   Lubricate valve stems with clean engine oil. Install new valve stem seals on each guide using seal installer tool - tap gently until seated. Insert valves into their original positions (or new valves if replacing worn units). Install valve springs with closer-wound coils toward cylinder head. Compress spring and install keepers in valve stem groove. Gently tap valve stem tip with plastic hammer to ensure keepers are fully seated. Verify each valve moves freely and springs are not binding.
10. 10

    Clean and prepare cylinder head mating surfaces
    Clean cylinder head mating surface with gasket scraper and solvent - surface must be completely free of old gasket material. Do not gouge aluminum surface. Clean engine block deck surface similarly. Use compressed air to blow out all coolant passages and oil return passages in head and block. Wipe surfaces with lint-free cloth and solvent. Inspect head bolt holes in block and clean threads with thread chaser if needed. Ensure bolt holes are dry - oil in holes will cause incorrect torque readings.
11. 11

    Install cylinder head with new gasket
    Place new cylinder head gasket on block with orientation marks (TOP or UP) facing upward. Align all coolant and oil passage holes. Do not use any sealant on head gasket. Carefully lower cylinder head onto block, aligning dowel pins. Install NEW cylinder head bolts finger-tight in all positions. Torque head bolts in proper sequence (center outward): First pass to 30 Nm, second pass to 65 Nm (48 lb-ft), then additional 90 degrees using angle gauge, then additional 90 degrees again (total 180 degrees after final torque). Bolts must be tightened in proper sequence in single session.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Install exhaust and intake manifolds
    Apply anti-seize compound to exhaust manifold stud threads. Install new exhaust manifold gasket and position exhaust manifold. Install nuts finger-tight, then torque in sequence from center (hottest area) toward ends to 30 Nm (22 lb-ft). Install new intake manifold gasket. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts in sequence to 25 Nm (18 lb-ft). Reconnect fuel rail assembly.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Install rocker arms and camshafts
    Lubricate all rocker arm contact surfaces with clean engine oil. Install rocker arms in their original positions. Ensure each rocker arm moves freely. Apply clean engine oil to all camshaft journals and lobes. Install intake camshaft first with timing marks in correct position, then exhaust camshaft. Install camshaft caps in correct positions and orientation (marked intake/exhaust and numbered). Tighten camshaft cap bolts in sequence from center outward in multiple passes (no more than 2 passes) to final torque of 14 Nm (10 lb-ft).
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)
14. 14

    Install timing chain components and valve cover
    Verify timing chain is still properly positioned on crankshaft sprocket. Install intake cam sprocket onto camshaft aligning previous paint marks. Hold camshaft with wrench on hex and torque sprocket bolt to 80 Nm (59 lb-ft). Repeat for exhaust cam sprocket. Compress timing chain tensioner using bench vise and install retaining pin or clip. Install tensioner with new gasket and torque bolt to 25 Nm (18 lb-ft). Remove tensioner pin to release tension. Rotate crankshaft two complete revolutions clockwise and verify timing marks realign correctly. Clean valve cover gasket surfaces. Install new valve cover gasket. Position valve cover and install bolts in sequence from center outward to 10 Nm (7 lb-ft).
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts15 Nm (11 lb-ft)
15. 15

    Reassemble remaining components and refill fluids
    Reinstall upper timing cover with new gasket. Install turbocharger with new gasket and torque mounting nuts. Reconnect turbo oil feed and return lines with new crush washers. Install new spark plugs (do not overtighten in aluminum head). Install ignition coils and reconnect electrical connectors. Reconnect all coolant hoses, vacuum lines, and remaining electrical connections per photos taken during disassembly. Install new oil filter and refill engine with 4 quarts Honda Genuine 0W-20 oil. Refill cooling system with 6 quarts Honda Type 2 Blue coolant through radiator cap and reservoir. Reconnect battery.

Reassembly

1. Double-check all electrical connectors, vacuum hoses, and coolant hoses are properly connected
2. Verify timing chain tensioner retaining pin was removed and tensioner is functioning
3. Ensure all tools and rags are removed from engine compartment
4. Check that all bolts have been torqued to specification in proper sequence

Verification

• With spark plugs still out and fuel pump fuse removed, crank engine several times to prime oil system and verify no unusual noises
• Reinstall fuel pump fuse and spark plugs, start engine and allow to idle - monitor for oil pressure light and unusual sounds
• Check for coolant, oil, or exhaust leaks around head gasket, valve cover, manifolds, and turbo connections
• Allow engine to reach operating temperature while monitoring coolant level - top off as needed and burp air from system
• Perform test drive at varying loads and RPM ranges - listen for valve train noise, check for smooth power delivery
• After engine cools, recheck valve cover bolt torque and inspect for any fluid leaks
• Check engine oil level and condition after test drive - change oil after 100 miles if metal particles present
• Consider performing compression test and leak-down test to verify valve sealing quality

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