Honda S2000 clutch removal applies to 1999-2003 models.

SPECIAL TOOLS NEEDED

• Clutch alignment shaft 07LAF-PT00110
• Remover handle 07936-3710100
• Ring gear holder 07LAB-PV00100 or 07924-PD20003
• Driver 07749-0010000
• Attachment, 32 x 37 mm 07746-0010200

Pressure Plate and Clutch Disc Removal

1. Check the height-variation of the diaphragm spring fingers using the dial indicator. If the variation is more than the service limit, replace the pressure plate. See figure.

• Standard (New): 0.4 mm (0.016 in.) max.
• Service Limit: 0.6 mm (0.024 in.)

2. Install the special tools. See figure.
3. To prevent warping, unscrew the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure plate.
4. Remove the release bearing from the pressure plate.
5. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area. See figure.
6. Inspect the surface of the pressure plate for wear, cracks, and burning.
7. Inspect for warpage using a straight edge and feeler gauge. Measure across the pressure plate. If the warpage is more than the service limit, replace the pressure plate. See figure.

• Standard (New): 0.03 mm (0.001 in.) max.
• Service Limit: 0.15 mm (0.006 in.)

8. Remove the clutch disc and special tools. See figure.
9. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is soaked with oil, replace it. Find the source of the oil leak if the clutch disc is soaked.
10. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. See figure.

• Standard (New): 8.2-8.9 mm (0.32-0.35 in.)
• Service Limit: 6.0 mm (0.24 in.)

11. Measure the rivet depth from the clutch disc lining surface to the rivets, on both sides. If the rivet depth is less than the service limit, replace the clutch disc. See figure 1 of 2. See figure 2 of 2.

• Standard (New): 1.2-1.7 mm (0.047-0.067 in.)
• Service Limit: 0.2 mm (0.008 in.)

Flywheel Inspection

1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
3. Measure the flywheel runout using a dial indicator through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended. See figure.

• Standard (New): 0.05 mm (0.002 in.) max.
• Service Limit: 0.15 mm (0.24 in.)

4. Turn the inner race of the ball bearing with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing. See figure.

Flywheel Replacement

1. Install the special tool. See figure.
2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.
3. Remove the ball bearing from the flywheel. See figure.
4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface. See figure.
5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts, finger-tight.
6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. See figure.

Release Bearing Inspection

Check the play of the release bearing by spinning it with your hand, if there is excessive play, replace the release bearing with a new one. See figure.

The release bearing is packed with grease. Do not wash it in solvent.

Clutch Disc and Pressure Plate Installation

1. Apply a thin, uniform coat of super high temp urea grease (PN 08798-9002) to the splines of the clutch disc. Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
2. Install the ring gear holder. See figure.
3. Install the clutch disc using the special tools.
4. Apply super high temp urea grease (PN 08798-9002) into the groove of the release bearing, then install the release bearing on the pressure plate. See figure.
5. Install the pressure plate and the mounting bolts, finger-tight. Make sure the release bearing does not come off.
6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. See figure.
   • PRESSURE PLATE MOUNTING BOLT TORQUE: 25 N.m (2.6 kgf.m, 19 lbf.ft)
7. Remove the special tools.
8. Make sure the diaphragm spring fingers are all the same height.

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1. Remove the banjo bolt and washers, then disconnect the clutch hose from the slave cylinder. Plug the end of the clutch hose with a shop towel to prevent brake fluid from coming out.

Honda S2000 1999-2003 Model

Honda S2000 2004 Model

2. Remove the two bolts and slave cylinder.
3. Pull back the boot, and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod. Reinstall the boot. See figure.
4. Apply super high temp urea grease (PN 08798-9002) to the tip of the slave cylinder rod.
5. Install the slave cylinder in the reverse order of removal. Use new banjo bolt washers. Make sure the boot is installed on the slave cylinder.
6. Bleed the clutch hydraulic system.

• Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
• Make sure there is an adequate supply of fluid at the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose.
• Tighten the bleeder screw to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft); do not overtighten it.
• Refill the clutch master cylinder with fluid when done.
• Use only Honda DOT 3 brake fluid from an unopened container.
• Confirm clutch operation, and check for leaking fluid.

7. Make sure the fluid level in the reservoir is at the MAX (upper) level line. See figure.

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The delay orifice mechanism improves clutch operation by delaying the slave cylinder release speed when the clutch pedal is suddenly released. The delay orifice mechanism is built into the slave cylinder.

When the clutch pedal is pressed, the fluid pressure from the master cylinder moves the one-way valve in the direction shown in the illustration. The fluid flows through two passages: the orifice part and the filter part. It then flows out to the slave cylinder to release the pressure plate and clutch disc joint.

When the clutch pedal is released, the fluid pressure from the slave cylinder moves the one-way valve in the direction shown in the illustration. The one-way valve blocks the filter-part passage and delays the clutch release speed by returning the fluid to the master cylinder through only the orifice-part passage.

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Clutch pedal adjustment applies to Honda S2000 1999-2003 models.

• Check the clutch pedal position switch.
• Check the clutch interlock switch.
• The clutch is self-adjusting to compensate for wear.
• If there is no clearance between the master cylinder piston and pushrod. The release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.

1. Loosen the locknut, and back off the clutch switch until it no longer touches the clutch pedal.
2. Loosen the locknut, and turn the pushrod in or out to get the specified height and stroke at the clutch pedal.

• Clutch Pedal Stroke: 115-125 mm (4.53-4.92 in.)
• Clutch Pedal Height: 189 mm (7.44 in.)

3. Tighten the locknut .
4. With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.
5. Turn in the clutch pedal position switc an additional 3/4 to 1 turn.
6. Tighten the locknut.
7. Loosen the locknut and the clutch interlock switch.
8. Press the clutch pedal to the floor.
9. Release the clutch pedal 15-20 mm (0.59-0.79 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch so the engine will start with the clutch pedal in this position.
10. Tighten the locknut.

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Honda S2000 F20C VTEC solenoid applies to 1999-2003 AP1 models.

1. Disconnect the 1P connector from the VTEC solenoid valve.
2. Measure resistance between the terminal and body ground.
   • Resistance: 14-30 ohm



3. If the resistance is within specifications, remove the VTEC solenoid valve assembly from the cylinder head, and check the VTEC solenoid valve filter for clogging. If there is clogging, replace the engine oil filter, VTEC solenoid valve filter, and the engine oil.
   
4. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve is normal, check the engine oil pressure.
   

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Honda S2000 trunk components and testing applies to 1999-2003 models.

Trunk Wiring Diagram

SWITCH TEST

1. Remove the rear console.
2. Disconnect the 2P connector from the switch.
3. Check for continuity between the No. 1 and No. 2 terminals.

• There should be continuity when the switch is pushed.
• There should be no continuity when the switch is released.

4. If the continuity check is not as specified, replace the switch.

SOLENOID TEST

1. Open the trunk lid.
2. Disconnect the 3P connector from the trunk latch.
3. Check solenoid operation by connecting power and ground according to the table. To prevent damage to the solenoid, apply battery voltage only momentarily.
   
4. If the solenoid does not operate as specified, replace it.

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ROCKER ARM TEST

Special Tools Required

• Gauge joint adapter 07LAK-PR3A101
• VTEC air adapter (2) 07ZAJ-PNAA100
• Air joint adapter 07ZAJ-PNAA3000
• Air pressure regulator 07AAJ-PNAA100

1. Remove the cylinder head valve cover.
2. Set the No. 1 piston at top dead center (TDC) (see step 2 on Valve Clearance Adjustment).
3. Move the secondary rocker arm for No. 1 cylinder. The secondary rocker arm should move independently of the mid rocker arm.

• If the secondary rocker arm does not move, remove the mid, primary, and secondary rocker arms as an assembly, and check that the pistons in the mid and primary rocker arms move smoothly.
• If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly.

4. Check that the air pressure on the shop air compressor gauge indicator is over 400 kPa (4 kgf/cm2 , 57 psi). Make sure no water in the air hose and air compressor tank.
5. Inspect the valve clearance (see Valve Clearance Adjustment).
6. Remove the No. 3 and No. 4 camshaft holder bolts, and install the VTEC air adapters finger-tight.

7. Install the gauge joint adapter to the inspection hole.
8. Connect the air joint adapter to the VTEC air adapters.
9. Connect the air pressure regulator to the air joint adapter.
10. With the specified air pressure applied and the piston at TDC, move the secondary rocker arm. The mid rocker arm, primary rocker arm, and secondary rocker arm should move together. If the three rocker arms do not move together, replace the rocker arms as a set.

11. Remove the special tools.
12. Tighten the camshaft holder bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
13. Install the cylinder head cover.

ROCKER ARM AND SHAFT INSPECTION

1. Remove the dipstick, positive crankcase ventilation (PCV) hose and breather hose (see step 18 on Cylinder Head Removal ).
2. Remove the ignition coil cover, then remove the ignition coils (see step 19 on Cylinder Head Removal ).
3. Remove the cylinder head cover (see step 22 on Cylinder Head Removal ).
4. Loosen the rocker arm adjusting screws (see step 28 on Cylinder Head Removal ).
5. Remove the camshaft holders and camshafts.
6. Insert the bolts into the rocker shaft holder, then remove the rocker arm assembly (see step 30 on Cylinder Head Removal ).
7. Measure the diameter of the shaft at the first rocker location.

8. Zero the gauge to the shaft diameter.

9. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition.

• Rocker Arm-to-Shaft Clearance:
  • Standard (New): 0.021-0.041 mm (0.0008-0.0016 in.)
  • Service Limit: 0.07 mm (0.003 in.)

10. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all overtolerance rocker arms. If any rocker arm needs replacement, replace all three rocker arms in that set (primary, mid, and secondary).
11. Inspect the rocker arm pistons. Push each piston manually. If it does not move smoothly, replace the rocker arm assembly.

• When reassembling the primary rocker arm, carefully apply air pressure to its oil passage
• Apply new engine oil to the pistons when reassembling

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Hub and knuckle assembly removal applies to Honda S2000 1999-2003 models.

REMOVAL

1. Loosen wheel lug nuts slightly. Raise and support vehicle. Remove wheel assembly. Pry lock tab away from spindle nut and remove nut. Remove brake hose mounting bolts. Remove caliper assembly, and hang the caliper to one side with wire. DO NOT put weight on flexible brake line.
2. Remove the ABS wheel sensor wire bracket. Remove the wheel sensor from knuckle. Do NOT disconnect the sensor connector. Remove brake disc retaining screws. Install two 8 x 1.25-mm bolts in brake disc, and tighten bolts to force brake disc from hub. Remove cotter pin and nut from tie rod end. Using Ball Joint Remover (07MAC-SL00200), separate tie rod ball joint and lift tie rod end out of knuckle.
3. Remove cotter pin from lower control arm ball joint, and remove nut. Using ball joint separator, separate lower ball joint from control arm.
4. Remove hub/knuckle from control arm. Remove cotter pin and nut from upper ball joint. Using ball joint remover, separate ball joint from upper control arm. Slide axle shaft from knuckle and hub assembly. Support axle shaft with wire. Remove hub/knuckle assembly. Remove dust cover, spindle nut and ABS pulser ring from hub assembly.

INSTALLATION

To install hub/knuckle, reverse removal procedure. Tighten bolts and nuts to specification. Use NEW spindle nut, and stake after tightening.

TORQUE SPECIFICATIONS Ft. Lbs. (N.m)

• Ball Joint Nut
  • Upper: 29-35 (39-47)
  • Lower: 43-51 (59-69)
• Brake Caliper Mounting Bolt: 81 (110)
• Lower Control Arm Pivot Bolt: 58 (78)
• Spindle Nut: 242 (329)
• Stabilizer Bar Mounting Bolts: 29 (39)
• Strut Assembly Shaft Nut: 22 (29)
• Strut Fork Pinch Bolt: 32 (43)
• Strut Fork-To-Control Arm Nut: 47 (64)
• Tie Rod Lock Nut: 40 (54)
• Upper Control Arm Anchor Bolt Nut: 47 (64)
• Upper Control Arm Bushing Bolt: 97.6 (132)
• Upper Strut Mounting Nut: 36 (49)
• Wheel Lug Nut 80 (108)
• Brake Line Clamp Bolt 62 INCH Lbs. (7.0 N.m.)

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Flywheel removal and installation applies to Honda S2000 1999-2003 models.

Special Tools Required

• Ring gear holder 07LAB-PV00100

1. Remove the transmission.
2. Remove the pressure plate and clutch disk.
3. Remove the eight flywheel bolts, then separate the flywheel from the crankshaft flange.




4. Now is a good time to install a lighter performance flywheels from USDM and JDM manufacturers like Toda, Jun, Exedy, ACT, HKS, J’s Racing, Spoon, Mugen, etc. Stick with the brand names for durability. After installation, tighten the bolts in the sequence shown.
5. Install the pressure plate and clutch disk. We highly recommend installing clutch kits from ACT, Spoon and Mugen. The OEM S2k clutch is known to not last very long.
6. Install the transmission.

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Honda S2000 cylinder head removal and installation applies to 1999-2003 models.

CYLINDER HEAD REMOVAL PROCEDURE

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.

HONDA S2000 F20C CYLINDER HEAD INSTALLATION PROCEDURE

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).

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.

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