Honda Civic manuals

Honda Civic Service Manual: Connecting Rod and Crankshaft End Play Inspection (R18A9)

Honda Civic Service Manual / Powertrain / Engine / Engine Block / Cylinder Block / Connecting Rod and Crankshaft End Play Inspection (R18A9)

Removal

1. Intake Manifold and Throttle Body Assembly (Natural Gas Model)

1.

Remove the intake air duct.


2.

Remove the heater hose clamp bracket.



3.

Disconnect the water bypass hoses (A).


4.

Disconnect the PCV hose (B).


5.

Disconnect the connectors (C).


6.

Remove the harness clamps (D).


7.

Remove the intake manifold bracket.


8.

Remove the intake manifold and throttle body assembly from the cylinder head.


2. Engine Wire Harness

1.

Remove the engine wire harness.


3. Automatic Transmission Assembly (A/T)

1.

Remove the automatic transmission.


4. Drive Plate Assembly

1.

Remove the drive plate (A) and the washer (B).


5. A/F Sensor (Sensor 1)


1.

Disconnect the connector.


2.

Remove the A/F sensor (A).


6. Exhaust Chamber Cover (Natural Gas Model)

1.

Remove the exhaust chamber cover (A).


7. Catalytic Converter (Natural Gas Model)


1.

Remove the catalytic converter (A).


2.

Remove the catalytic conveter cover (B).


8. Thermostat Housing (Natural Gas Model)

1.

Remove the thermostat housing.


9. Alternator

1.

Remove the alternator.


10. Lower Torque Rod Bracket (A/T)

1.

Remove the lower torque rod bracket.


11. Intermediate Shaft Assembly

1.

Remove the crankshaft position (CKP) sensor cover (A).


2.

Remove the intermediate shaft (A) from the differential.


NOTE: Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal (B).


12. A/C Compressor Bracket

1.

Remove the A/C compressor bracket.


13. Water Pump Pulley

1.

Remove the water pump pulley.


14. Auto Tensioner Assembly


1.

Remove the drive belt auto-tensioner (A).


2.

Check for oil leaks from the drive belt auto-tensioner damper (B) and check for damage to the damper rubber.


15. Cylinder Head Cover and/or Packing


1.

Remove the dipstick (A).


2.

Disconnect the breather hose (B).


3.

Remove the cylinder head cover.


16. Check The No.1 Piston at Top Dead Center (With Cam Chain Case/Oil Pump)

1.

Set the No. 1 piston at top dead center (TDC). The ‘‘UP’’ mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.


17. Crankshaft Pulley

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1.

Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).


2.

Remove the bolt with a socket, 19 mm (C) and a breaker bar.


3.

Remove the crankshaft pulley.


18. Engine Oil Pump Assembly

1.

Disconnect the PCV hose.


2.

Remove the oil pump.


19. Cam Chain Auto-Tensioner

1.

Measure the tensioner rod length between the tensioner body and bottom of the flat surface section on the tensioner rod. If the length is more than the service limit, replace the cam chain.


Tensioner Rod Length

Service Limit:

14.5 mm (0.571 in)



2.

Loosely install the crankshaft pulley.


3.

Turn the crankshaft counterclockwise to compress the auto-tensioner.



4.

Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B).


5.

Insert a 1.0 mm (1/32 in) diameter pin (C) into the holes.


6.

Turn the crankshaft clockwise to secure the pin.


NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.



7.

Remove the cam chain auto-tensioner.


8.

Remove the crankshaft pulley.


20. Cam Chain


1.

Remove the cam chain guide (A) and the cam chain tensioner arm (B).


2.

Remove the cam chain.


21. Cylinder Head Assembly


1.

Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence, 1/3 turn at a time, repeat the sequence until all bolts are loosened.


2.

Remove the cylinder head.


22. Oil Pan Assembly

1.

Using a flat blade screwdriver, separate the oil pan from the lower block in the places shown.


2.

Remove the oil pan.


23. Engine Oil Strainer

1.

Remove the oil strainer.


24. Engine Baffle Plate

1.

Remove the baffle plate.


Inspection

1. Connecting Rod and Crankshaft End Play - Inspection

1.

Measure the connecting rod end play with a feeler gauge (A) between the connecting rod (B) and the crankshaft (C).


Connecting Rod End Play

Standard (New):

0.15-0.35 mm (0.0059-0.0138 in)

Service Limit:

0.45 mm (0.0177 in)



2.

If the connecting rod end play is beyond the service limit, install a new connecting rod, and recheck. If it is still beyond the service limit; replace the crankshaft.


3.

Push the crankshaft firmly away from the dial indicator by prying, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator by prying; the dial reading should not exceed the service limit.


Crankshaft End Play

Standard (New):

0.10-0.35 mm (0.0039-0.0138 in)

Service Limit:

0.45 mm (0.0177 in)



4.

If the crankshaft end play is beyond the service limit, replace the thrust washers and recheck. If it is still beyond the service limit, replace the crankshaft.


Installation

1. Engine Baffle Plate

1.

Install the baffle plate.


2. Engine Oil Strainer

1.

Install the oil strainer (A) with new O-ring (B).


3. Oil Pan Assembly

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1.

Remove all of the old liquid gasket from the oil pan mating surfaces, the bolts, and the bolt holes.


2.

Clean and dry the oil pan mating surfaces.


3.

Apply liquid gasket, (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pan, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


NOTE:

Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.



4.

Install the dowel pins (A).


5.

Install the oil pan (B) with new O-rings (C).


6.

Tighten the bolts in three steps. In the final step, torque all bolts, in sequence, to 18 N·m (1.8 kgf·m, 13 lbf·ft). Wipe off the excess liquid gasket on the each side of crankshaft pulley and flywheel/drive plate.


NOTE:

Wait at least 30 minutes before filling the engine with oil.

Do not run the engine within 3 hours after installing the oil pan.


4. Cylinder Head Assembly


1.

Clean the cylinder head and the engine block surface.


2.

Install a new coolant separator (A) in the engine block whenever the engine block is replaced.


3.

Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.


4.

Install the cylinder head on the engine block.


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5.

Measure the diameter of each cylinder head bolt at point A and point B.


6.

If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.



7.

Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.


8.

Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·ft). Use a beam-type torque wrench. When using a preset click-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 from the first step.


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9.

After torquing, tighten all cylinder head bolts in two steps (90 ° per step using the sequence shown in step 8). If you are using a new cylinder head bolt, tighten the bolt an extra 60 °.


NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure. Do not loosen it back to the specified angle.


5. Set The No.1 Piston at Top Dead Center (Without Cam Chain Case/Oil Pump)

1.

Set the camshaft to TDC. The ‘‘UP’’ mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.


6. Cam Chain

1.

Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the mark (B) on the crankshaft sprocket.


2.

Install the cam chain on the camshaft sprocket with the colored link plate (A) aligned with the mark (B) on the camshaft sprocket.


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3.

Install the cam chain guide (A) and the cam chain tensioner arm (B).


7. Cam Chain Auto-Tensioner

1.

Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.0 mm (1/32 in) diameter pin back into the holes (F).


NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.


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2.

Install the cam chain auto-tensioner.


3.

Remove the pin from the cam chain auto-tensioner.


8. Engine Oil Pump Assembly


1.

Check the oil pump oil seal for damage. If the oil seal is damaged, replace the oil seal.


2.

Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.


3.

Clean and dry the oil pump mating surfaces.


4.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


NOTE:

Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A), (B), and (C).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


5.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.


Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


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6.

Set the edge of the oil pump (A) on the edge of the oil pan (B) with new O-rings (C).


7.

Install the oil pump on the engine block (D).


8.

Loosely install the dowel bolts (E), then tighten the 8mmbolts (F), the 6 mm bolts (G) and the dowel bolts.


9.

Wipe off the excess liquid gasket on the oil pan and oil pump mating surface.


NOTE:

When installing the oil pump, do not slide the bottom surface onto the oil pan mounting surface.

Wait at least 30 minutes before filling the engine with oil.

Do not run the engine within 3 hours after installing the oil pump.


9. Crankshaft Oil Seal, Transmission side


1.

Apply a light coat of new engine oil to the crankshaft and the lip of the crankshaft oil seal.


2.

Use the driver handle and the oil seal driver attachment, 96 mm to drive a new crankshaft oil seal (A) squarely into the engine block to the specified installed height.


3.

Measure the distance between the engine block (A) and the crankshaft oil seal (B).


Oil Seal Installed Height:

0.2-1.2 mm (0.008-0.047 in)


10. Crankshaft Pulley


1.

Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D).


2.

Lubricate with new engine oil as shown.


3.

Install the crankshaft pulley (A) onto the crankshaft (B) by aligning the flat sides (C) of the pulley with the flat sides (D) of the inner oil pump gear.


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When a new crankshaft or a new pulley bolt is installed


4.

Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), torque the bolt to 180 N·m (18.4 kgf·m, 133 lbf·ft) with a torque wrench and a socket (C), then remove the bolt.


5.

Torque the bolt to 50 N·m (5.1 kgf·m, 37 lbf·ft) with a torque wrench and a socket.


NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.


6.

Tighten the bolt an additional 82 °.


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When the crankshaft or the pulley bolt is reused


7.

Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), then torque the bolt to 70 N·m (7.1 kgf·m, 52 lbf·ft) with a torque wrench and a socket (C).


NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.


8.

Tighten the bolt an additional 90 °.


11. Valve Clearance Adjustment

1.

Set the No. 1 piston at top dead center (TDC). The ‘‘UP’’ mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.


2.

Select the correct feeler gauge for the valve clearance you are going to check.


Valve Clearance

Intake:

0.18-0.22 mm (0.008-0.008 in)

Exhaust:

0.23-0.27 mm (0.010-0.010 in)

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3.

Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag.



4.

If you feel too much or too little drag, loosen the locknut, and turn the adjusting screw (A) until the drag on the feeler gauge is correct.


5.

Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.


Specified Torque

7 x 0.75 mm

14 N·m (1.4 kgf·m, 10 lbf·ft)

Apply new engine oil to the nut threads.



6.

Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.


7.

Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.



8.

Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.


9.

Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.



10.

Rotate the crankshaft clockwise. Align the No. 2 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.


11.

Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.


12. Cylinder Head Cover and/or Packing


1.

Thoroughly clean the head cover gasket and the groove.


NOTE: Check and, if necessary, replace the head cover gasket.


2.

Install the head cover gasket (A) in the groove of the cylinder head cover (B).


3.

Make sure the head cover gasket is seated securely.


4.

Clean the head cover contacting surfaces with a shop towel.



5.

Remove the old liquid gasket from the top edge matting surfaces of the oil pump (A) and cylinder head (B).


6.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the chain case contact areas. Install the component within 5 minutes of applying the liquid gasket.


NOTE:

Apply a 5 mm (0.20 in) diameter bead of liquid gasket to the mating surfaces (C).

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.



7.

Install the cylinder head cover.


8.

Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 10 N·m (1.0 kgf·m, 7 lbf·ft).


NOTE:

Wait at least 30 minutes before filling the engine with oil.

Do not run the engine for at least 3 hours after installing the head cover.



9.

Connect the breather hose (A).


10.

Install the dipstick (B).


13. Auto Tensioner Assembly

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1.

Install the drive belt auto-tensioner.


14. Water Pump Pulley

1.

Install the water pump pulley.


15. A/C Compressor Bracket

1.

Install the A/C compressor bracket.


16. Intermediate Shaft Assembly

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1.

Insert the intermediate shaft (A) into the differential correctly.


NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal (B).


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2.

Install the crankshaft position (CKP) sensor cover (A).


17. Lower Torque Rod Bracket (A/T)

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1.

Install the lower torque rod bracket.


18. Alternator

1.

Install the alternator.


19. Thermostat Housing (Natural Gas Model)

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1.

Install the thermostat housing (A), using a new gasket (B) and new O-ring (C).


20. Catalytic Converter (Natural Gas Model)

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1.

Install the catalytic conveter cover (A).


2.

Install the catalytic converter (B) with new gaskets (C).


21. Exhaust Chamber Cover (Natural Gas Model)

1.

Install the exhaust chamber cover (A).


22. A/F Sensor (Sensor 1)


1.

Install the A/F sensor (A).


2.

Connect the connector.


23. Drive Plate Assembly

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1.

Install the drive plate (A) and the washer (B), and tighten the eight bolts in a crisscross pattern in at least two steps.


24. Automatic Transmission Assembly (A/T)

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1.

Install the automatic transmission.


25. Engine Wire Harness

1.

Install the engine wire harness.


26. Intake Manifold and Throttle Body Assembly (Natural Gas Model)


1.

Install the intake manifold and throttle body assembly (A) with new gaskets (B).


2.

Tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.


3.

Install the intake manifold bracket.



4.

Connect the PCV hose (A).


5.

Connect the connectors (B).


6.

Install the harness clamps (C).


7.

Connect the water bypass hoses (D).


8.

Install the heater hose clamp bracket.


9.

Install the intake air duct.


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