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Engine Block Overhaul: Installation: Procedure

WARNING: This page is about a different variant/trim than selected.
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 1: Exploded View Of Engine Block Overhaul Components For Installation (1 Of 2)
GHH378351Courtesy of HONDA, U.S.A., INC.
*1 These parts have inspection items
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 2: Exploded View Of Engine Block Overhaul Components With Torque Specifications For Installation (2 Of 2)
GHH378352Courtesy of HONDA, U.S.A., INC.
Torque: N.m (kgf.m, lbf.ft)
Replace
*1 These parts have inspection items
  1. Piston Pin - Install
    GHH378353Courtesy of HONDA, U.S.A., INC.
    		 1. Install a piston pin snap ring (A) only on one side.

    2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.
    GHH378354Courtesy of HONDA, U.S.A., INC.
    		 3. Heat the piston to about 158°F (70°C).
    GHH378355GHH378356Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    GHH378355GHH378356Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    		 4. Assemble the piston (A) and the connecting rod (B).

    NOTE:  Align the mark (C) with the groove (D) direction on the connecting rod as shown.

    5. Install the piston pin (E).

    6. Install the remaining snap ring (F).

    7. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.
  2. Piston Ring - Install
    GHH378357GHH378358GHH378359Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    GHH378357GHH378358GHH378359Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    GHH378357GHH378358GHH378359Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    		 1. Apply new engine oil to the piston rings.

    2. Install the top ring and the second ring as shown. The top ring (A) has a 1R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must be facing upward.
    GHH378360Courtesy of HONDA, U.S.A., INC.
    		 3. Rotate the rings in their grooves to make sure they do not bind.

    4. Position the ring end gaps as shown.
  3. Piston/Connecting Rod Assembly - Install
    GHH378361Courtesy of HONDA, U.S.A., INC.
    		 1. Remove the connecting rod caps. Check that the bearing is securely in place.

    2. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.

    3. Position the mark (A) to face the cam chain side of the engine.
    GHH378362Courtesy of HONDA, U.S.A., INC.
    		 4. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Push down on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.

    5. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
  4. Oil Jet and Oil Jet Bolt - Install
  5. Main Bearing Clearance - Check
  6. Sealing Bolt - Install (if necessary)
  7. Drain Bolt - Install (if necessary)
  8. L Side Cover - Install (if necessary)
  9. CKP Pulse Plate - Install
    GHH378363Courtesy of HONDA, U.S.A., INC.

    NOTE: 

    • Apply new engine oil to the threads and flange of the CKP pulse plate mounting bolts.
    • Position the mark (A) facing it out side and align the portion (B) on the CKP pulse plate and groove (C) on the crankshaft.
  10. Crankshaft - Install

    NOTE: 

    • Apply a coat of new engine oil to the main bearings and the connecting rod bearings.
    • Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, then lower the crankshaft into the engine block.
  11. Thrust Washer - Install
    GHH378364Courtesy of HONDA, U.S.A., INC.
    		 1. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block.
  12. Lower Block and Bearing Half - Install
    GHH378365Courtesy of HONDA, U.S.A., INC.
    		 1. Apply liquid gasket to the engine block mating surface of the lower block, and to the inside edge of the threaded bolt holes.

    2. Put the lower block on the engine block.

    3. Apply new engine oil to the threads and flange of the bearing cap bolts.

    4. Torque the bearing cap bolts, in sequence, to 30 N.m (3.1 kgf.m, 22 lbf.ft).
    GHH378366Courtesy of HONDA, U.S.A., INC.
    		 5. Tighten the bearing cap bolts an additional specified angle.
    Specified Angle: 50° 
    GHH378367Courtesy of HONDA, U.S.A., INC.
    		 6. Torque the 8 mm bolts, in sequence, to the specified torque.
  13. Connecting Rod Bearing Clearance - Check
  14. Connecting Rod Bearing Cap and Bearing Half - Install
    GHH378368Courtesy of HONDA, U.S.A., INC.
    		 1. Measure the diameter of each connecting rod bolt at point A and point B.

    2. Calculate the difference in diameter between point A and point B.

    Point A-Point B = Difference in Diameter 

    3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

    Difference in Diameter 

    Specification:  0-0.1 mm (0-0.004 in) 
    GHH378369Courtesy of HONDA, U.S.A., INC.
    		 4. Apply new engine oil to the threads and flanges of the connecting rod bolts and the bearing half.

    5. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the bearing cap.

    6. Install the bearing caps and the bolts finger-tight.

    7. Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the bearing cap.

    8. Install the bearing caps and the bolts finger-tight.

    9. Torque the connecting rod bolts to 20 N.m (2.0 kgf.m, 15 lbf.ft).
    GHH378370Courtesy of HONDA, U.S.A., INC.
    		 10. Tighten the connecting rod bolts an additional 90°.
    NOTE:  Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle.
  15. Engine Block Heat Insulator - Install (if necessary)
  16. Oil Control Orifice - Install (if necessary)
  17. Crankshaft Sprocket - Install
    GHH378371Courtesy of HONDA, U.S.A., INC.
    		 1. Install the crankshaft sprocket.

    2. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.
  18. Balancer Chain - Install
    GHH378372Courtesy of HONDA, U.S.A., INC.

    NOTE:  These colored link plates (A) shall be used in product process only and not used for maintenance purpose. There is no need to line up the colored link plates as it has no effect on the engine operation.

  19. Balancer Chain Guide - Install
  20. Transmission End Crankshaft Oil Seal - Install
  21. Balancer Shaft/Balancer Shaft Holder Assembly - Install 
  22. Oil Pan - Install 
  23. Cylinder Head - Install
  24. Drive Plate - Install 
  25. Transmission (e-CVT) - Install
  26. Engine - Install 
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