Service Bulletin
Contents
1. 02 047 2 Turn the right cylinder bank s camshaft pulley clockwise with a socket and ratchet The pulley clicks and stops several times Stop the pulley when its green mark aligns with the valve cover timing mark NOTE You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the valve cover timing mark RIGHT CYLINDER BANK VALVE COVER TIMING MARK GREEN MARK 3 Turn the left cylinder bank s camshaft pulley clockwise with a socket and ratchet The pulley clicks and stops several times Stop the pulley when its green mark aligns with the timing belt cover bolt hole NOTE You may need to rotate the camshaft pulley up to four complete turns before its green mark aligns directly with the bolt hole LEFT CYLINDER BANK VALVE COVER TIMING MARK 4 Rotate the left cylinder bank s camshaft pulley clockwise another 1 4 turn to align its green mark with the valve cover timing mark 3 of 12 TIMING BELT INSTALLATION NOTE 1 Do not install the timing belt until you are sure the camshafts camshaft pulleys and crankshaft timing pulley are in their correct timed positions Left and right engine callouts are from the driver s seat With the green direction arrows on the timing belt pointing clockwise slip the belt over the right camshaft pulley so its solid white line the line closest to the direction arrows aligns with the mark2. N NI N N oh ea oh aK tA o TIN A TPL N N N OX O N O N N I 5 N N N N N N N N N N N NI N 911 NO NO N N N Tt t t N N N N N N N N N N N asured along the top row of the chart and draw line of the shim you removed down the left hand column of the chart D N N N N AN s L Go o a a A AJ AAJ AA a NANI NG OAN NO t N N N N oON SNISNIS A A a NA VA VA NIQ a t cO N ON AN OW AY SITY CY N AY SIX OY DI gt a N wo S N of NIV SIN a a a al aol N a al al N af N N N Nj AN AN AN N NGN NANI AN NG AND NN NGN N oO S N eN lo oN sN eN oN sN 4 l I Jo lo o K IN 90 N D IS Jo A A a NA VA VA A a NAN VA A a No o No SN NN ol st ah o eN oA sN tN N of a ffs 5 S N wo 5 N rte NI SI S co S N S N al A S N S N G o AJ a NS NG A af a Aa AANA AA AN NG AANA NS N 9 N Jo Jo sN eN a N eN eN sN
3. eN BSE AE N 0 N S USA NS N N 5 295 lt 5 a A a VA NS A a VA Vo NS NS A a a a No SN NN N oA st NN oA aN N a 8 o c o G o N N O N N S N NI D os Sis s S AJNA NG A a NN NS ANAT Z S sss to N S oc sss MeN N u G iL iL B N ANA OOO N ENR VASA OREO A AEE PaRa Fara Ara x A 11 of 12 02 047 SSW 5 N 48 0 50 0 52 ROC d clear nce 0 38mm exhaust valve 44 0 46 0 0 40 0 42 t 38 0 0 36 0 34 VALVE SHIM REPLACEMENT CHART placement shim is a 276 022 0 38 clearanc 268 shim t 28 0 30 0 32 0 0 02 047 12 of 12
4. slight angle making the drag a little more than it would be on other engines 02 047 4 For valves with the correct clearance draw an X in the appropriate circle on the Valve Inspection Chart For valves with incorrect clearances write down the clearance you measured in the circle VALVE INSPECTION CHART Example for 1 Cylinder In this example the clearance of the front exhaust valve is incorrect 0 37 mm The clearance of the other three valves is OK 5 Rotate the camshaft pulley until the dual timing dots exhaust camshaft and single timing dot intake camshaft align with the timing dots on the camshaft drive gear 6 Lock the camshaft gear to its subgear with a 5 x 0 8 mm bolt through either side of the hole in the gears This holds the spring loaded subgear in place so you can remove the camshaft Do this for each camshaft you need to remove Insert bolt here RE RIGHT EXHAUST 22 RI RIGHT INTAKE gt CAMSHAFT GEARS CAMSHAFT GEAR 4 j RIGHT CAMSHAFT ne SINGLE TIMING DOTS Insert bolt LE LEFT EXHAUST LEFT Wa CAMSHAFT GEAR 1 P A N LEFT DUAL TIMING DOTS 7 Remove the camshaft bearing caps noting the location and direction of each cap 8 Remove the camshaft s 02 047 10 11 12 13 14 15 16 For each valve needing adjustment do steps 10 thru 13 Insert a pick or a sm
5. 2 86 mm 8 97149 285 0 5514542 290 2 90 mm 8 97149 287 0 5514567 294 2 94mm 8 97149 289 0 5514583 298 2 98 mm 8 97149 291 0 5514609 302 3 02 mm 8 97149 293 0 5514625 02 047 September 17 2002 REQUIRED SPECIAL TOOLS NOTE For additional special tools you may need refer to the appropriate service manual Flange Holder 07RAB TB4010B Holder Handle T N 07 001020 Gear Spring Lever T N J 42686 Universal Holder T N J 43041 Valve Adjuster Holder T N J 42689 AH Large Binder Clip 2 required Commercially available CYLINDER HEAD REMOVAL NOTE Page references are to the 2002 Passport Service Manual and the 2002 Passport Fuel amp Emissions Manual 1 Remove the hood see page 8F 15 of the service manual 2 Disconnect the negative cable from the battery 3 Remove the air cleaner See page 6E2 543 of the fuel amp emissions manual 4 Remove the radiator upper fan shroud see page 6B 8 of the service manual 5 Remove the drive belt tensioner and the drive belt see page 6B 11 of the service manual 6 Remove the cooling fan assembly 4 bolts and the cooling fan pulley 7 Remove the power steering pump see page 2A 23 of the service manual 8 Drain the engine coolant see page 6B 5 of the service manual 9 Drain the engine oil 10 Remove the crankshaft pulley e Attach the flange holder T N O7RAB TB4010B with the holder handle T N 07 001020 to
6. cam lobe presses the valve fully open 9 On the tappet side closest to the bearing cap insert the valve adjuster holder T N J 42689 AH between the camshaft and the tappet The tool should rest on the edge of the tappet without touching the shim VALVE AN SA V r ADJUSTER I J Vy HOLDER J Rotate into place I between tappet camshaft A ys Cam lobe down 10 Slowly turn the crankshaft or camshaft pulley counterclockwise so that when the valve closes the tool catches between the camshaft and the tappet holding the valve slightly open NOTE Do not turn the crankshaft or camshaft pulley too far or in the wrong direction If you do you might break the tool or worse yet damage the cylinder head 11 Insert a pick or a small screwdriver into the tappet notch and pry out the shim 12 Wipe off the shim then write its number on the Valve Inspection Chart for that valve and cylinder If there is no number on the shim measure its thickness with a micrometer and write down the measurement on the Valve Inspection Chart 13 Follow the directions on the Valve Shim Replacement Chart to select the correct shim 8 of 12 14 Insert the correct shim number side down into the tappet Make sure the shim is fully seated SHIM Number side faces down 15 Release and remove the tool by turning the crankshaft or camshaft pulley clockwise 16 Turn the crankshaft or camshaft pulley
7. replace the timing belt CAMSHAFT SUBGEAR PRELOADING GEAR TIMING AND CAMSHAFT INSTALLATION NOTE The Passport V6 engine has a non interference design This means the valves never contact the pistons even when the valves or camshafts are not correctly timed or even if a valve is fully open and its piston is at top dead center TDC The ratio between the camshaft drive gear and the camshaft gears is 1 33 to 1 This means the timing dots on a correctly timed camshaft will only align with the dots on the camshaft drive gears every 4th turn of the camshaft pulley The left and right intake camshafts are different On the cam lobe side of the camshaft gear the left intake camshaft is marked LI and it has dual timing dots the right intake camshaft is marked RI and it has a single timing dot The left and right exhaust camshafts are the same On the cam lobe side of the camshaft gear both camshafts are marked LE and RE and both have dual timing dots and a single dot Service manual page references are to the 2002 Passport Service Manual 1 Before you install the camshafts preload the subgears preloading must be done whenever you remove the bearing caps from a camshaft Make sure the spring is installed between the camshaft gear and the subgear With the camshaft held in a soft jawed vise attach the gear spring lever T N J 42686 to the subgear then turn the subgear until
8. the position of each camshaft bearing cap and valve train part before you remove it When you assemble the head install the marked parts in their original positions Service manual page references to the 2002 Passport Service Manual 1 Remove the camshaft drive gear camshafts and valve train parts as needed for inspection or repair see pages 6A 48 and 6A 49 of the service manual 2 Clean the bare head to remove all varnish carbon and grime 3 Check the cylinder head and gasket and repair the head if needed see page 6A 49 of the service manual 2 of 12 CAMSHAFT INSPECTION NOTE Service manual page references are to the 2002 Passport Service Manual 1 Inspect the camshaft journal oil clearances and thrust clearances See page 6A 62 of the service manual If any clearances are not within specification replace the cylinder head s 2 Inspect the camshaft lobe heights journal diameters and runout see page 6A 61of the service manual If any measurements are not within specification replace the camshaft s 3 If any camshaft or camshaft drive gear is seized or if the engine is seized from other mechanical causes inspect the camshaft drive gear dowel pins and the camshaft gears Check the dowel pins for damage and replace the drive gear assemblies as needed DOWEL PINS RIGHT CAMSHAFT DRIVE GEAR LEFT CAMSHAFT DRIVE GEAR Inspect the camshaft gears for movement
9. the pulley While holding the pulley with the tool remove the pulley bolt and the pulley Install the pulley bolt When needed later this will allow you to turn the crankshaft by hand 11 Remove the cylinder head covers see pages 6A 19 and 6A 21 of the service manual 12 Remove the timing belt see TIMING BELT REMOVAL on page 3 2002 American Honda Motor Co Inc All Rights Reserved ATB 23043 0209 1 of 12 Skil Level CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment R and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an REPAIR authorized Honda automobile dealer 13 Remove the common chamber see page 6A 22 steps 2 thru 8 of the service manual 14 Remove the exhaust manifolds see pages 6A 24 and 6A 25 of the service manual 15 Remove the cylinder heads Loosen the head bolts the sequence shown below Remove and discard the head bolts Remove the cylinder heads CYLINDER HEAD DISASSEMBLY NOTE e Whether you re rebuilding a cylinder head or assembling a new one mark
10. 1 of the service manual Measure the valve clearances using the Go No Go method see the note below The clearances must be e Intake valves 0 28 mm 0 05 mm Exhaust valves 0 30 mm 0 05 mm NOTE To measure with the Go No Go method use two feeler gauges one to measure the smallest allowable clearance and the other to measure the largest If the small gauge fits and the large gauge doesn t the valve adjustment is OK If the small gauge doesn t fit or if the large gauge slides easily the valve needs adjustment The feeler gauges slide through the clearance gap at a slight angle making the drag little more than it would be on other engines For valves with the correct clearance draw an X in the appropriate circle on the Valve Inspection Chart For valves with incorrect clearances write down the clearance you measured in the circle VALVE INSPECTION CHART Example for 1 Cylinder YO In this example the clearance of the front exhaust valve is incorrect 0 37 mm The clearance of the other three valves is OK DS If you need to replace a valve shim turn the crankshaft or camshaft until the cam lobe for the valve points away from the valve 7 of 12 7 Turn the valve tappet with a pick or a small screwdriver until the tappet notch is within the indentation in the head TAPPET NOTCH INDENTATION 8 Turn the crankshaft or camshaft pulley clockwise until the
11. HONDA Service Bulletin Applies 1998 02 Passport ALL Cylinder Head Service BACKGROUND In the 1998 through 2002 Passport Service Manuals some of the information on cylinder head service timing belt installation camshaft gear timing and valve adjustment is incomplete For complete information use this service bulletin along with the appropriate service manual and fuel amp emissions manual This service bulletin covers these topics Cylinder head removal page 1 e Cylinder head disassembly page 2 Camshaft inspection page 2 Cylinder head installation page 3 Timing belt removal page 3 Engine timing page 3 Timing belt installation page 4 Camshaft subgear preloading gear timing and camshaft installation page 5 Valve adjustment page 7 Valve Inspection Chart page 10 Valve Shim Replacement Chart page 11 PARTS INFORMATION NOTE For additional parts you need refer to the Parts Catalog Cylinder Head Cover Gaskets P N 8 97170 239 1 H C 5517909 Cylinder Head Bolts 16 required P N 8 97011 998 2 H C 4396446 Valve Shims While 41 shims are available the 10 sizes below will cover most valve adjustments Shim Size P N H C 266 2 66 mm 8 97149 275 0 5514443 270 2 70 mm 8 97149 277 0 5514468 274 2 74 mm 8 97149 279 0 5514484 278 2 78 8 97149 281 0 5514500 282 2 82 mm 8 97149 283 0 5514526 286
12. NTAKE SIDE 6 of 12 4 Install the intake and exhaust camshafts in the right cylinder bank Set the camshaft marked RI into the intake side of the head Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear Set the camshaft marked RE and LE into the exhaust side of the cylinder bank with RE at the 12 o clock position Make sure the single timing dot on the camshaft gear aligns with the timing dot on the camshaft drive gear RIGHT BANK Cylinders 1 3 and 5 RE RIGHT EXHAUST CAMSHAFT GEAR RI RIGHT INTAKE CAMSHAFT GEAR gt 3 SINGLE TIMING DOTS BRUE 5 Install the left cylinder bank intake and exhaust camshafts Set the camshaft marked LI into the intake side of the head Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear Set the camshaft marked LE and RE into the exhaust side of the cylinder bank with LE at the 12 o clock position Make sure the dual timing dots on the camshaft gear align with the timing dot on the camshaft drive gear LEFT BANK LI LEFT INTAKE CAMSHAFT GEAR LE LEFT EXHAUST CAMSHAFT GEAR LEFT CAMSHAFT DRIVE GEAR N 02 047 6 VALVE ADJUSTMENT 5 Install the camshaft bearing caps in the same removed them NOTE On the right cylinder bank the di
13. all screwdriver into the tappet notch and pry out the shim Wipe off the shim then write its number on the Valve Inspection Chart for that valve and cylinder If there is no number on the shim measure its thickness with a micrometer and write down the measurement on the Valve Inspection Chart Follow the directions on the Valve Shim Replacement Chart to select the correct shim Insert the correct shim number side down into the tappet Make sure the shim is fully seated SHIM Number side faces down Install the camshafts see steps 2 thru 9 of CAMSHAFT SUBGEAR PRELOADING GEAR TIMING AND CAMSHAFT INSTALLATION Rotate the camshaft pulleys a few turns to ensure the new shims are fully seated Recheck the clearances of the valves you adjusted with the Go No Go method see step 3 If any clearances are incorrect readjust them 9 of 12 VALVE INSPECTION CHART OOVOC 0 00 00 6 Q Right Cylinder Bank Left Cylinder Bank FRONT OF ENGINE Directions Check the clearance of each valve 12 intake and 12 exhaust If a valve s clearance is correct draw an X in the circle that represents that valve If its clearance is incorrect measure the actual clearance and write the number in the circle for that valve NOTE Left and right cylinder bank designations are from the drivers seat 10 of 12 02 047 Measured Clearance VALVE SHIM REPLACEMENT CHART N CK OK th OK N
14. and correct positioning on the camshafts If the gears are not stationary or if their positions are incorrect replace the camshaft s The keyway should align with the top center of the 3 front cam lobes 02 047 CYLINDER HEAD INSTALLATION NOTE Service manual page references are to the 2002 Passport Service Manual 1 After making the needed inspections or repairs install the cylinder heads with new head bolts see page 6A 34 of the service manual 2 Installall parts you removed in the reverse order of removal see page 6A 30 of the service manual TIMING BELT REMOVAL NOTE Left and right engine callouts are from the driver s seat 1 Remove the timing belt covers in this order right left then lower 2 Loosen don t remove the tensioner pulley bolt is 2 Saw a AK NG Cy TENSIONER PULLEY PULLEY TENSIONER BOLT PULLEY BOLT hae IDLER LOWER PULLEY TENSIONER BOLT Jj CRANKSHAFT TENSIONER PUSHER TIMING PULLEY 3 Remove the idler pulley bolt and let the idler pulley pivot towards the crankshaft timing pulley 4 Remove the lower tensioner bolt and the tensioner pusher 5 Carefully remove the timing belt from the pulleys ENGINE TIMING 1 Turn the crankshaft timing pulley until its notch aligns with the mark on the oil pump housing NOTE The crankshaft timing pulley may have a green mark 180 degrees from its keyway Do not use this mark to set the crankshaft position
15. clockwise until the cam lobe again points away from the valve 17 Recheck the valve clearance using the Go No Go method see step 4 e Ifthe clearance is OK repeat steps 6 thru 17 for the other valves needing adjustment e If the clearance is still incorrect repeat steps 6 through 17 until it is correct then adjust the remaining valves 18 Turn the camshaft pulleys until the single timing dot right cylinder bank and dual timing dots left cylinder bank align with the single timing dots on the camshaft drive gears 19 Install the cylinder head covers with new gaskets see pages 6A 20 and 6A 21 Torque the cover bolts to 9 N m 6 5 lb ft Off Vehicle Valve Adjustment 1 a copy of the Valve Inspection Chart on page 11 2 Make acopy of the Valve Shim Replacement Chart on pages 12 and 13 then tape the pages together side by side 3 Measure the valve clearances using the Go No Go method see the note below The clearances must be e Intake valves 0 28 mm 0 05 mm e Exhaust valves 0 30 mm 0 05 mm NOTE To measure with the Go No Go method use two feeler gauges one to measure the smallest allowable clearance and the other to measure the largest If the small gauge fits and the large gauge doesn t the valve adjustment is OK If the small gauge doesn t fit or if the large gauge slides easily the valve needs adjustment The feeler gauges slide through the clearance gap at
16. its threaded hole lines up with the hole in the camshaft gear Lock the subgear to the camshaft gear with a 5 x 0 8 mm bolt through either side of the gear hole Preload the subgears on the other camshafts GEAR SPRING CAMSHAFT GEAR BOLT Either side 5 of 12 2 On the right cylinder bank turn the camshaft pulley until its green mark is at 12 o clock in relation to the head surface at the center of the head Turning the pulley brings the timing dots on the camshaft drive gear into their correct position to the left and right of the gear s centerline RIGHT CYLINDER BANK VALVE COVER 12 o clock At center of head L by TIMING MARK Z GREEN MAR CENTERLINE TIMING RIGHT CAMSHAFT DRIVE GEAR Ne INTAKE SIDE EXHAUST SIDE 3 On the left cylinder bank turn the camshaft pulley until its green mark is at 12 o clock in relation to the head surface at the center of the head Then turn the pulley counterclockwise until its green mark points close to the timing belt cover bolt hole Turning the pulley brings the timing dots on the camshaft drive gear into their correct position to the left and right of the gear s centerline LEFT CYLINDER BANK 12 o clock At center of head Hpi KP 25 2 7 OF Z BOLT HOLE 4 VALVE 5 COVER TIMING K MARK GREEN MARK CENTERLINE TIMING DOTS BOLT HOLE N LEFT CAMSHAFT DRIVE GEAR Su EXHAUST SIDE I
17. new tensioner pusher comes with its pin held compressed by a special wire If you install a new tensioner pusher save the wire for future use 02 047 7 Install the tensioner pusher e Install the lower bolt loosely e Push the tensioner pusher up against the tensioner pulley then install the upper bolt and torque it to 25 18 lb ft Torque the lower bolt to 25 18 lb ft TENSIONER PULLEY 2 TENSIONER Q PUSHER LOWER BOLT UPPER BOLT 8 Remove the wire or paper clip from the tensioner pusher and remove the binder clips from the camshaft pulleys 9 Verify the timing belt is correctly installed e Rotate the crankshaft three complete turns not two turns as stated in the service manual Align the crankshaft timing pulley notch with the mark on the oil pump housing Check the green marks on both camshaft pulleys they should line up with the valve cover timing marks NOTE After you rotate the crankshaft the solid white lines on the belt will not align with the camshaft pulley marks this is normal PULLEY MARKS CAMSHAFT PULLEYS CRANKSHAFT TIMING PULLEY IL PUMP PULLEY NOTCH 10 Remove the crankshaft bolt then install the lower the right and the left timing belt covers Torque the cover bolts to 19 14 Ib ft 02 047 11 Install the crankshaft pulley and torque the bolt to 167 123 lb ft 12 Install any other parts you removed to
18. on the pulley Secure the belt to the pulley with a large binder clip SOLID WHITE LINE BINDER CLIP Wrap the timing belt around the bottom of the water pump pulley and draw it tight Slip the timing belt over the left camshaft pulley so its other solid white line the one farthest from the direction arrows aligns with the mark on the pulley Secure the belt to the pulley with a large binder clip BINDER CLIP SOLID WHITE LINE 4 of 12 Wrap the timing belt around the inner side of the idler pulley then slip the belt over the crankshaft timing pulley with its dotted white line aligned to the green mark on the crankshaft timing pulley NOTE For correct belt stretch the dotted line must meet the green mark on the crankshaft timing pulley at the 9 o clock position lf there isn t enough slack to slip the belt over the pulley in the correct position turn the crankshaft a few degrees counterclockwise install the belt then turn the crankshaft back to the 9 o clock position CRANKSHAFT TIMING PULLEY DOTTED WHITE LINE GREEN MARK Place the tensioner pusher in a soft jawed vise then slowly compress the tensioner pusher pin until it lines up with the two small holes in the tensioner pusher housing HEAVY DUTY PAPER CLIP PIN Compressed TENSIONER PUSHER Insert a straightened heavy duty paper clip through the holes in the housing This will hold the pin in its compressed position NOTE A
19. rectional arrows on the bearing caps should point towards the front of the engine On the left bank the arrows should point towards the rear of the engine Install the bearing cap bolts then torque them to 10 7 lb ft in the sequence shown below INTAKE EXHAUST Remove the bolts used to hold the preload of the camshaft subgears If not already done inspect the camshaft thrust clearances see page 6A 62 of the service manual If any clearances are not within specification replace the cylinder head s NOTE Valve adjustment can be done either on vehicle or off vehicle To measure exhaust valves you need a 0 25 mm and a 0 35 mm feeler gauge To measure intake valves you need a 0 23 mm and a 0 33 mm feeler gauge Since these are odd sizes you may need to stack two gauges for example 0 11 mm and 0 12 mm to make 0 23 mm If you do this make sure the gauges are clean and in good condition If you re not sure the gauge stack is correct measure it with a micrometer Service manual page references are to the 2002 Passport Service Manual 6 02 047 On Vehicle Valve Adjustment locations and directions they were before you 1 Make a copy of the Valve Inspection Chart on page 11 Make a copy of the Valve Shim Replacement Chart on pages 12 and 13 then tape the pages together side by side Remove the cylinder head covers see pages 6A 19 and 6A 2
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