Engine Mechanical - 2.0L (Hatchback): Diagnosis Honda Civic VII рестайлинг

VTEC ROCKER ARM TEST

Special Tools Required

1. Air pressure regulator 07AAJ-PNAA100
2. VTEC air adapter 07ZAJ-PNAA100
3. VTEC air stopper 07ZAJ-PNAA200
4. Air joint adapter 07ZAJ-PNAA300

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1. Remove the cylinder head cover (see «CYLINDER HEAD COVER REMOVAL»(ref-173867-S11518418012005032300000) ).
2. Set the No. 1 piston at top dead center (TDC) (see step 1 of «CAM CHAIN REMOVAL»(ref-173867-S19381854442005032300000) ).
3. Verify that the intake primary rocker arm (A) moves independently of the intake secondary rocker arm (B). If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. If the intake primary rocker arm moves freely, go to step 4.
4. Repeat step 3 on the remaining intake primary rocker arms with each piston at TDC. When all the primary rocker arms pass the test, go to step 5.
5. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm 2 , 58 psi).
6. Inspect the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(ref-173867-S12334035752005032300000) ).
7. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B).
8. Remove the No. 2 and No. 3 camshaft holder bolts, and install the VTEC air adapters (C) finger-tight.
9. Connect the air joint adapter (D), and air pressure regulator (E).
10. Loosen the valve on the regulator, and apply the specified air pressure. Specified Air Pressure: 290 kPa (3.0 kgf/cm 2 , 42 psi) NOTE: If the synchronizing piston does not move after applying air pressure; move the primary or secondary rocker arm up and down manually by rotating the crankshaft clockwise.
11. With the specified air pressure applied, move the intake primary rocker arm (A) for the No. 1 cylinder. The primary rocker arm and secondary rocker arm (B) should move together. If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly, and check that the pistons in the primary and secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test.
12. Remove the special tools.
13. Tighten the camshaft holder mounting bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
14. Tighten the sealing bolt to 20 N.m (2.0 kgf.m, 14 lbf.ft).
15. Install the cylinder head cover (see «CYLINDER HEAD COVER INSTALLATION»(ref-173867-S33220876932005032400000) ).

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1. Remove the cam chain (see «CAM CHAIN REMOVAL»(ref-173867-S19381854442005032300000) ).
2. Loosen the rocker arm adjusting screws (see «ROCKER ARM ASSEMBLY REMOVAL»(ref-173867-S26952556522005032300000) ).
3. Remove the camshaft holder (see «ROCKER ARM ASSEMBLY REMOVAL»(ref-173867-S26952556522005032300000) ).
4. Remove the intake camshaft.
5. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator.
6. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape.
7. Punch a hole through the tape over one of the advance holes.
8. Apply air to the advance hole to release the lock.
9. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator.
10. Make sure the punch marks on the VTC actuator and exhaust camshaft sprocket are facing up, then set the camshafts in the head (see step 6 of «ROCKER ARM ASSEMBLY INSTALLATION»(ref-173867-S04252301602005032400000) ).
11. Set the camshaft holders and chain guide B in place (see step 7 of «ROCKER ARM ASSEMBLY INSTALLATION»(ref-173867-S04252301602005032400000) ).
12. Tighten the camshaft holder bolts to the specified torque (see step 8 of «ROCKER ARM ASSEMBLY INSTALLATION»(ref-173867-S04252301602005032400000) ).
13. Install the cam chain (see «CAM CHAIN INSTALLATION»(ref-173867-S01441306562005032300000) ).
14. Adjust the valve clearance (see «VALVE CLEARANCE ADJUSTMENT»(ref-173867-S12334035752005032300000) ).

CAMSHAFT INSPECTION

Note. Do not rotate the camshaft during inspection.

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1. Remove the rocker arm assembly (see «ROCKER ARM ASSEMBLY REMOVAL»(ref-173867-S26952556522005032300000) ) and disassemble it (see «ROCKER ARM & SHAFT DISASSEMBLY/REASSEMBLY»(ref-173867-S12084856022005032300000) ).
2. Put the rocker shaft holders, camshaft, and camshaft holders on the cylinder head, then tighten the bolts to the specified torque. NOTE: If the engine does not have bolt (21), skip it and continue the torque sequence. (Scheme 347) Specified Torque: 8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbf.ft) 6 mm bolts: 12 N.m (1.2 kgf.m, 8.7 lbf.ft) 6 mm bolts (21), (22), (23): (Scheme 347)
3. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head
4. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth and read the end play. If the end play is beyond the service limit, replace the camshaft head and recheck. If it is still beyond the service limit, replace the cylinder. Camshaft End Play: Standard (New): 0.05-0.20 mm (0.002-0.008 in.) Service Limit: 0.4 mm (0.02 in.)
5. Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.
6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.
7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.
8. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 2.
9. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. If the camshaft-to-holder clearance is within limits, go to step 11. If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head. If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): No. 1 Journal: 0.030-0.069 mm (0.001-0.003 in.) No. 2, 3, 4, 5 Journals: 0.060-0.099 mm (0.002-0.004 in.) Service Limit: 0.15 mm (0.006 in.)
10. Check the total runout with the camshaft supported on V-blocks. If the total runout of the camshaft is within the service limit, replace the cylinder head. If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the service limit, replace the cylinder head. Camshaft Total Runout: Standard (New): 0.03 mm (0.001 in.) Max. Service Limit: 0.04 mm (0.002 in.)
11. Measure cam lobe height.

Inspection

Note. Inspect the piston, piston pin, and connecting rod when they are at room temperature.

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1. Measure the diameter of the piston pin. Piston Pin Diameter: Standard (New): 21.961-21.965 mm (0.8646-0.8648 in.) Service Limit: 21.953 mm (0.8643 in.)
2. Zero the dial indicator to the piston pin diameter.
3. Check the difference between the piston pin diameter and piston pin hole diameter in the piston. Piston Pin-To-Piston Clearance: Standard (New): -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) Service Limit: 0.005 mm (0.0002 in.)
4. Measure the piston pin-to-connecting rod clearance. Piston Pin-To-Connecting Rod Clearance: Standard (New): 0.005-0.015 mm (0.0002-0.0006 in.) Service Limit: 0.02 mm (0.0008 in.)

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1. Install a piston pin snap ring (A).
2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil.
3. Heat the piston to about 158°F (70°C).
4. Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D), and the embossed mark (E) on the same side.
5. Install the remaining snap ring (F).
6. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.

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1. Remove the piston from the cylinder block (see «CRANKSHAFT & PISTON REMOVAL»(ref-173867-S28140544312005032400000) ).
2. Using a ring expander (A), remove the old piston rings (B).
3. Clean all ring grooves thoroughly with a squared-off broken ring or ring groove cleaner with a blade to fit the piston grooves. The top and 2nd ring grooves are 1.2 mm (0.05 in.) wide. The oil ring groove is 2.0 mm (0.08 in.) wide. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
4. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.6-0.8 in.) from the bottom.
5. Measure the piston ring end-gap (B) with a feeler gauge: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits (see step 4 of «BLOCK & PISTON INSPECTION»(ref-173867-S22447029102005032400000) ). If the bore is over the service limit, the cylinder block must be rebored. Piston Ring End-Gap: Top Ring: Standard (New): 0.20-0.35 mm (0.008-0.014 in.) Service Limit: 0.60 mm (0.024 in.) Second Ring: Standard (New): 0.40-0.55 mm (0.016-0.022 in.) Service Limit: 0.70 mm (0.028 in.) Oil Ring: REKEN Manufactured Ring: Standard (New): 0.25-0.65 mm (0.010-0.026 in.) Service Limit: 0.75 mm (0.030 in.) FEDERAL MOGUL Manufactured Ring: Standard (New): 0.20-0.70 mm (0.008-0.028 in.) Service Limit: 0.80 mm (0.031 in.)
6. Install the top ring and second ring as shown. The top ring (A) has a 1R mark or no mark and the second ring (B) has a 2R mark or 2ND mark. The marks must be facing upward.
7. Rotate the rings in their grooves to make sure they do not bind.
8. Position the ring end gaps as shown
9. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance: Standard (New): 0.035-0.060 mm (0.0014-0.0024 in.) Service Limit: 0.13 mm (0.005 in.) Second Ring Clearance: Standard (New): REKEN Manufactured Ring: 0.030-0.055 mm (0.0012-0.0022 in.) FEDERAL MOGUL Manufactured Ring: 0.025-0.060 mm (0.0010-0.0024 in.) Service Limit: 0.13 mm (0.005 in.)

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1. Set the crankshaft to 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 the engine.
4. 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.
5. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
6. Check the connecting rod bearing clearance with plastigage (see «ROD BEARING CLEARANCE INSPECTION»(ref-173867-S22056637782005032400000) ).
7. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-173867-S32505897702005032400000) ).
8. Apply new 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°.

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1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
2. Position the arrow (A) facing the cam chain side of the engine.
3. 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 at top dead center.

Scheme 368

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 Difference In Diameter Specification: 0-0.1 mm (0-0.004 in.)
3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.