blbarretts2k

Hey

I just ordered a new polished valve cover for my 2003 S2000.

I've reviewed the Honda service manual on the removal and installation.
It all seems pretty straight forward. However, the area up next to the firewall
seems a bit tight and might pose some problems when lifting the Stock cover off.

Has anyone made this modification? and if so would you please share your experience on the above mentioned issue?

All other install/removal tips are welcome too.


Thanks in advance

Stratocaster

The installation time is about 15 minutes. These are basic installation instructions, written from memory, so please us your common sense. I might have forgotten something.



1. Remove the black "Vtec" spark plug cover.

2. Remove the oil dip stick and set aside.

3. Remove the 4 bolts holding the spark plug coils.

4. Remove the spark plug coils and set aside.

5. Disconnect the connectors from both of the temp sensors from the rear of the valve cover 6. Pull the PCV Valve from the valve cover and set on the intake manifold.

7. Disconnect the wiring harness for the firewall. This lets the harness more just enough to get the valve cover off.

8. Lift the wiring harness out of the valve cover and pull towards the battery. It will just clear the cover.

9. Remove the 4 bolt holding the cover in place.

10. Pull the valve cover towards the exhaust manifold and it should "snap" free.

11. Slowly lift the cover off, avoiding the wiring harness.

12. With the old cover off, remove the PVC Valve gasket and install in your new cover.

13. Remove the metal/rubber gasket that the last 4 bolts held in place.

You will reuse these.

14. Remove the head to valve cover gasket from either the valve cover or the head. Mine stayed on the head, but I have seen them come up with the valve cover too.

15. Install the head to valve cover gasket in your new valve cover.



Install the cover and use steps 1-11 in reverse order.

ruexp67

Take off the igintion cover

Removed the coil packs

Disconnect the sensor on the front passenger side and rear drivers side

Disconnect the wire loom that runs along the back of the engine compartment from its mount. It is between the cover and the firewall. There is a small clip on the bottom, squeeze that then pull toward the front of the motor.

Pull the PCV Valve out completely from the valve cover.

Using pliers move the clip that holds the breather hose on, then remove the breather hose.

Remove the dipstick, and the oil cap.

Then remove the 5 bolts holding the cover on.

If you order from Rick's I believe you get a new gasket set, if not buy one it's less than $15 from http://www.hardtopguy.com

Transfer the two sensors over from one cover to the other.

Put the new gasket on the new cover

Guide it down in place.

It won't sit all the way down at first. Replace the 5 screws using the new washer/gaskets from the kit. Tighten them in sequence according to the manual. I did it in three steps, but I am kinda anal that way. Check periodically to make sure the cover is seated properly (not too far forward or back.)

Replace the coils and the wiring, the PCV, the breather, the dipstick and the oil cap.

No need to drain or refil a drop.

First time took me about 45 mins. Now, 15mins.

blbarretts2k

thanks for the step by step

one more thing.

when lifting the cover off....

is there a method such as:
lift the back side up first (closest to firewall), then continue to lift the rest at that angle until the cover is free.

?

sorry to be so specific, but I'm trying to troubleshoot any issues I might run into.

ruexp67

LOL. Mine was from memory too.

BTW -- '04+ cars the PCV actuall screws to the cover so you should disconnect the hose, and then you can remove the PCV valve off the car.

ruexp67

Pull, it comes out. Not rocket science.

blbarretts2k

Awesome!!! I was worrying for nothing then

thanks