crankshaft HONDA CIVIC 2002 7.G Owner's Manual

8.
9.
lf the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new,
complete bearing with the same color code(s), and
recheck the clearance. Do not file. shim, or scrape
the bearings or the caps to adjust clearance.
lf the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance agaln. lf the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearing, replace the crankshaft and stan over.
Rod Bearing Selection
1. Inspect each connecting rod for cracks and heat
damage.
Connecting Rod Big End Eore Code Locations
2. Each rod has a tolerance range from 0 0.024 mm
(0.0009 in.), in 0.006 mm (0.0002 in.) increments,
depending on the size of its big end bore. lt's then
stamped with a number or bar (1, 2,3 or 4/1, ll,lll, ol
llll) indicating the range. You may find any
combination of numbers and bars in any engine.(Half the number or bar is stamped on the bearing
cap, the other half on the rod.)
lf you can't read the code because of an
accumulation of oil and varnish. do not scrub it
with a wire brush or scraper. Clean it only with
solvent or detergent.
Normal Bore Size: 48.0 mm 11.89 in.l
(cont'd)
7-9

Engine Block
Connecting Rod Bearing Replacement (cont'dl
Connecting Rod Journal Code Location
3. The connecting rod journalcodes are stamped on
the crankshaft.
Connecting Rod Journal Code Location (Letters or
Bars)
No.l JOURNAL No. 4 JOURNAL
7-10
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4. Use the big end bore codes and rod journalcodes
to select appropriate replacement bearings from
the following table.
NOTE:. Color code is on the edge of the bearing.. When using bearing halves of different colors, it
does not matter which color is used in the top or
bottom.
Big end ----------> Larger big end boreborecodolorl2oJll3 ol lll4 orllll
---------> Smallsrb.aring {Thickerl
PinkPink/YellowYollow/GrecnGreen
YellowYellow/GreenGreen/BrownBrown
GreenGreen/BrownErown/BlackBlack
BrownBrown/BlackBlack/BlueBlue
Rod
B
c
D
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(Thicker)
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Engine Block
Crankshaft and Piston Removal
1. Remove the engine assembly (see page 5-2).
2. Remove the transmission (see page 13-4).
3. Remove the oil pan (see page 7-1 1).
4. Remove the oil pump {see page 8-9).
5. Remove the cylinder head (see page 6-23).
6. Remove the baffle plates.
7. Remove the 8 mm bolts.
E
7-12
8. Remove the bearing cap bolts. To prevent warpage,
unscrew the bolts in sequence 1/3 turn at a time:
repeat the sequence until all bolts are loosened.
Remove the lower block and bearings, Keep all
bearings in order.
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10.Remove the rod caps/bearings. Keep all caps/
bearings in order.
Liftthe crankshaft out ofthe engine, being careful
not to damage the journals.
Remove the upper bearing halves from the
connecting rods. and set them aside with their
respective caps.
lf you can feel a ridge of metal or hard carbon
around the top of each cylinder, remove it with a
ridge reamer {A). Followthe reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they are pushed out.
11.
t.J.
14. Use the wooden handle of a hammer (A) to drive
out the pistons (B).
Reinstall the lower block and bearings on the
engine in the proper order,
Reinstallthe connecting rod bearings and caps
after removing each piston/connecting rod
assembly.
To avoid mixup on reassembly. mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it
indicates the rod bore size.
15.
to.
17.
7-13

Engine Block
Crankshaft lnspection
Out-ol-Round and Taper
1. Remove the crankshaft from the cylinder block (see
page 7-121.
2. Clean the crankshaft oil passages with pipe
cleaners or a suitable brush.
3. Clean the keyway and threads.
4. Measure out-of round at the middle of each rod and
main journal in two places. The difference between
measurements on each journal must not be more
than the service Iimit.
Journal Out-ot-Round
Standard (New): 0.005 mm (0.0002 in.) max.
Service Limit; 0.010 mm (0.0004 in.)
5. Measure taper at the edges of each rod and mainjournal. The difference between measurements on
each journal must not be more than the service
limit.
JournalTaper
Standard lNewl: 0.005 mm (0.0002 in.) max.
Service Limit: 0.010 mm {0.0004 in.)
I_JJ
fl
7-14
\
Straightness
6. Place the cylinder block on the surface plate.
7. Clean and installthe bearigns on the No.1 and No.5journal of the cylinder block.
8. Lower the crankshaft into the block.
9. Measure runout on all main journals. Rotate the
crankshaft two complete revolutlons. The
difference between measurements on each journal
must not be more than the service limit.
Crankshaft Total Runout
Standard (New): 0.03 mm 10.0012 in.l max.
Service Limit: 0.04 mm (0.0016 in.l
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1.
Block and Piston Inspection
Remove the crankshaft and pistons (se e pageT -121.
Check the piston for distortion or cracks,
Measure the piston diameter at a point I1 mm {0.4in.) from the bottom of the skirt. There are two
standard-size pistons (No Letter or A, and B). The
letter is stamped on the top of the piston. Letters
are also stamped on the block as cylinder bore
stzes.
Piston Diameter:
Standard (Newl:
No Letter {or A): 85.980 85.990 mm(3.3850 3.3854 in.)
B: 85.970-85.980 mm(3.3846-3.3850 in.)
Service Limit:
No Lefter lor A): 85.930 mm (3.3831 in.)
B: 85.920 mm 13.3827 in.)
Oversize Piston Diameter:
0.25: 86.230-85.240 mm (3.3949 -3.3953 in.l
4. Measure wear and taper in direction X and Y at
three levels in each cylinder as shown. lf
measurements in any cylinder are beyond the
oversize bore service limit. replace the block. lf the
block is to be rebored, refer to step 7 after reboring.
Cylinder Bore Size
Standard (New):
A or l: 86.010 86.020 mm
13.3862 3.3866 in.)
B or ll: 86.000 86.010 mm(3.3858 3.3862 in.)
Service Limit: 86.070 mm (3.3886 in.)
Oversize:
O.25t 96.250 86.260 mm (3.3957 3.3961 in.)
Reboring limit: 0.25 mm (0.01 in.l max.
Bore Taper:
Limit: (Difference between first and third
measurement) 0.05 mm (0.002 in.)
FirstMeasurement
SecondMeasutement
ThirdMeasurement
(cont'd)
7-15
6 mm {0.2 in.}
6 mm {0.2 in.}

Piston Installation
lf the crankshaft is already installed
1. Setthe crankshaftto bottom dead center (BDC) for
each cylinder.
2. Remove the connecting rod caps, then install the
ring compressor, and check that the bearing is
securely in place,
3. Position the arrow {A) facing the cam chain side of
rne engtne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A).
N4aintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal
alignment before pushing the piston into place.
Check the connecting rod bearing clearance withplastigage (see page 7-8).
lnspect the connecting rod bolts (see page 7 241.
Apply engine oil to the bolt threads, then install the
rod caps with bearings. Torque the bolts to 20 N.m
{2.0 kgf m, 14 lbf ft) + 90'.
6.
7.
2.
1.
lf the crankshaft is not installed
Remove the connecting rod caps. then install the
ring compressor, and check that the bearing is
securely in place.
Position the arrow (A)facing the cam chain side of
Ine engrne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A),
Maintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
4. Position all pistons attop dead center.
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7-23

Engine Block
Connecting Rod Bolt Inspection
Measure the diameter of each connectinq rod bolt
at Doint A and ooint B.
35 mm
Calculate the difference in diameter between point
A and point B.
Point A-Point B = Difference in Diameter
Diflerence in Diameter:
Specification: 0 0.1 mm (0 0.004 in.)
lf the difference in diameter is out of tolerance,
replace the connecting rod bolt.
1.
3,
mm
7-24
\-
Crankshaft Installation
Special Tools Bequired. Driver 07749-0010000. Attachment, 24 x 26 mm 07746-0010700. Oil seal driver attachment 96 o7ZAD-PNAAl00
1. Install the crankshaft end bushing with the special
tools when replacing the crankshaft. Drive in the
crankshaft end bushing until the special tools
bottom aqainst the crankshaft.
07749-0010000
07746-00'l
Check the connecting rod bearing clearance with
plastigage {see page 7-8).
Check the main bearing clearance with plastigage
(see page 7-6).
lnspectthe connecting rod bolts (see pageT-241.
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4.
a

5. Installthe bearing halves in the cylinder block and
conneclrng rods.
6. Apply a coat of engine oilto the main bearings and
rod bearings.
7. Hold the crankshaft so rod journal No.2and rodjournal No. 3 are straight up, and lower the
crankshaft into the block.
8. lnstallthe thrust washers (A) in the No. 4 journal of
the cylinder block.
Apply engine oil to the threads ot the connecting
rod bolts,
Seat the rod journals into connecting rod No. 1 and
connecting rod No. 4. Line up the mark (B) on the
connecting rod and cap, then installthe caps and
bolts finger-tight.
Rotate the crankshaft clockwise, and seat thejournals into connecting rod No.2 and connecting
rod No. 3. Line up the mark on the connecting rod
and cap, then install the caps and bolts finger-tight.
9.
10.
'11 .
\-1
12. Tighten the connecting rod bolts to 20 N.m(2.0 kgf.m, 14 lbf.ft).
13. Tighten the connecting rod bolts an additional 90".
14. Remove old liquid gasket from the lower block
mating surfaces, bolts and bolt holes.
15. Clean and dry the lower block mating surfaces.
16. Apply liquid gasket, P/N 08718-0009, evenly to the
cylinder block mating surface of the lower block
and to the innerthreads ofthe bolt holes.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
.\
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Apply liquid gasketalong the broken line.
7-25

Engine Block
Crankshaft Installation (cont'd)
Put the lower block on lhe cylinder block.
Tighten the bearing cap bolts in sequence to
29 N.m (3.0 kgf m, 22 lbf.ft).
Tighten the bearing cap bolts an additional 56".
Tighten the I mm bolts in sequence to 22 N.m 12.2kgf m, 16 lbf.ft).
'17 .
18.
19.
20.
7-26
{
2'1. Use the specialtools to drive a new oil seal
squarely into the block to the specified installed
height.
07749-0010000
Measure the distance between the crankshaft (A)
and oil seal (B).
Oil Seal Insialled Height: 5.5 6.5 mm
|10.22 0.26 in.l
5.5-6.5 mm{0.22 0.26 in.l
{\
07zAo-PNAA100