Engine Block: Overview Honda Element I

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1. Remove the oil pump (see «OIL PUMP REMOVAL»(ref-220565-S14117062592006022000000) ).
2. Remove the baffle plates (see step 8 ).
3. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft. Connecting Rod End Play Standard (New): 0.15-0.35 mm (0.006-0.014 in.) Service Limit: 0.40 mm (0.016 in.)
4. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance, replace the crankshaft (see «CRANKSHAFT AND PISTON REMOVAL»(ref-220563-S17367680632006022000000) ).
5. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10-0.35 mm (0.004-0.014 in.) Service Limit: 0.45 mm (0.018 in.)
6. If the crankshaft end play is out-of-tolerance, replace the thrust washers, and recheck. If it is still out-of-tolerance, replace the crankshaft (see «CRANKSHAFT AND PISTON REMOVAL»(ref-220563-S17367680632006022000000) ).

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1. Remove the lower block and bearing halves (see «CRANKSHAFT AND PISTON REMOVAL»(ref-220563-S17367680632006022000000) ).
2. Clean each main journal and bearing half with a clean shop towel.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and lower block, then torque the bolts to 29 N.m (3.0 kgf.m, 22 lbf.ft) + 56° using a commercially available torque angle gauge. NOTE: Do not rotate the crankshaft during inspection.
5. Remove the lower block and bearings again, and measure the widest part of the plastigage. Main Bearing-to-Journal Oil Clearance No. 1,2,4,5 Journals: Standard (New): 0.017-0.041 mm (0.0007-0.0016 in.) Service Limit: 0.050 mm (0.0020 in.) No. 3 Journal: Standard (New): 0.025-0.049 mm (0.0010-0.0019 in.) Service Limit: 0.055 mm (0.0022 in.)
6. If the plastigage measures too wide or too narrow, remove the crankshaft, and 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.
7. If 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 again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

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1. Numbers or letters or bars have been stamped on the end of the engine block as a code for the size of each of the five main journal bores. Write down the crank bore codes. If you can't read the codes because of accumulated dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Main Journal Code Location
2. The main journal codes are stamped on the crankshaft in either location.
3. Use the crank bore codes and crank journal codes to select the appropriate replacement bearings from the following table. NOTE: The 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.

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1. Remove the oil pump (see «OIL PUMP REMOVAL»(ref-220565-S14117062592006022000000) ).
2. Remove the baffle plates (see step 8 ).
3. Remove the connecting rod cap and bearing half.
4. Clean the crankshaft rod journal and bearing half with a clean shop towel.
5. Place plastigage across the rod journal.
6. Reinstall the bearing half and cap, and torque the bolts to 20 N.m (2.0 kgf.m, 14 lbf.ft) + 90° using a commercially available torque angle gauge. NOTE: Do not rotate the crankshaft during inspection.
7. Remove the rod cap and bearing half, and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance Standard (New): 0.020-0.050 mm (0.0008-0.0020 in.) Service Limit: 0.060 mm (0.0024 in.)
8. If 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.
9. If 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 again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearing, replace the crankshaft and start over.

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1. Inspect each connecting rod for cracks and heat damage. Connecting Rod Big End Bore Code Locations
2. Each rod has a tolerance range from 0 to 0.024 mm (0.0009 in.), and in 0.006 mm (0.0002 in.) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3, or 4/I, II, III, or IV) 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 is on the rod.) If 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: 51.0 mm (2.01 in.) Connecting Rod Journal Code Location
3. The connecting rod journal codes are stamped on the crankshaft in either location.
4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table. NOTE: The 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.

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1. Drain the engine oil (see ' «ENGINE OIL REPLACEMENT»(ref-220565-S33329839632006022000000) ).
2. If the engine is still in the vehicle, remove the subframe. 1 Attach the engine support hanger to the engine (see step 44 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 2 Disconnect the suspension lower arm ball joints (see «LOWER ARM REPLACEMENT»(ref-220587-S21965446392006022000000) ). 3 Remove the rear mount mounting bolts (see step 50 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 4 Remove the front mount mounting bolt (see step 51 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 5 A/T model: Remove the automatic transmission fluid (ATF) filter mounting bolt (see step 37 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 6 Make the appropriate reference lines at positions A and B that line up with the center of the subframe mounting bolts (see step 52 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 7 Attach the special tool to the subframe, then attach the jack to the special tool (see step 53 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ). 8 Remove the front subframe mounting bolts, then lower the subframe (see step 55 on «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ).
3. M/T model: Remove the stiffener.
4. Remove the bolts/nuts securing the oil pan.
5. Drive an oil pan seal cutter between the oil pan and engine block.
6. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan.
7. Remove the oil pan.

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1. Remove the engine assembly (see «ENGINE REMOVAL»(/honda/element/i-2004-2009/remont/mechanical/#engine) ).
2. Remove the transmission: Manual transmission (see «TRANSMISSION REMOVAL»(ref-220579-S23817130832006022000000) ) Automatic transmission (see «TRANSMISSION REMOVAL»(ref-220579-S23817130832006022000000) )
3. M/T model: Remove the pressure plate (see «PRESSURE PLATE AND CLUTCH DISC REMOVAL»(/honda/element/i-2004-2009/remont/clutches-manual-hydraulic/#clutch) ), clutch disc (see «PRESSURE PLATE AND CLUTCH DISC REMOVAL»(/honda/element/i-2004-2009/remont/clutches-manual-hydraulic/#clutch) ), and flywheel (see «FLYWHEEL INSPECTION»(/honda/element/i-2004-2009/remont/clutches-manual-hydraulic/#clutch) ).
4. A/T model: Remove the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-220581-S05335367122006022000000) ).
5. Remove the oil pan (see «OIL PAN REMOVAL»(ref-220563-S27838526862006022000000) ).
6. Remove the oil pump (see «OIL PUMP REMOVAL»(ref-220565-S14117062592006022000000) ).
7. Remove the cylinder head (see «CYLINDER HEAD REMOVAL»(ref-220562-S21256802072006022000000) ).
8. Remove the baffle plates.
9. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.
10. Remove the 8 mm bolts from the lower block in criss-cross pattern shown.
11. 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.
12. Remove the lower block and bearings. Keep all bearings in order.
13. Remove the rod caps/bearings. Keep all caps/bearings in order.
14. Lift the crankshaft out of the engine, being careful not to damage the journals.
15. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
16. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B).
17. Reinstall the lower block and bearings on the engine in the proper order.
18. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
19. To avoid mix up 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.

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1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-220563-S17367680632006022000000) ).
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 limit. Journal Out-of-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 main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.)

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1. 6) Place the engine block on the surface plate.
2. 7) Clean and install the bearings on the No. 1 and No. 5 journals of the engine block.
3. 8) Lower the crankshaft into the engine block.
4. 9) Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Runout Standard (New): 0.03 mm (0.0012 in.) max. Service Limit: 0.04 mm (0.0016 in.)

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1. Remove the crankshaft and pistons (see «CRANKSHAFT AND PISTON REMOVAL»(ref-220563-S17367680632006022000000) ).
2. Check the piston for distortion or cracks.
3. Measure the piston diameter at a point 13 mm (0.5 in.) 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 engine block as cylinder bore sizes. Piston Diameter Standard (New): No Letter (or A): 86.980-86.990 mm (3.4244-3.4248 in.) B: 86.970-86.980 mm (3.4240-3.4244 in.) Service Limit: No Letter (or A): 86.930 mm (3.4224 in.) B: 86.920 mm (3.4220 in.) Oversize Piston Diameter 0.25: 87.230-87.240 mm (3.4342-3.4346 in.)
4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the engine block. If the engine block is to be rebored, refer to step 7 after reboring. Cylinder Bore Size Standard (New): A or I: 87.010-87.020 mm (3.4256-3.4260 in.) B or II: 87.000-87.010 mm (3.4252-3.4256 in.) Service Limit: 87.070 mm (3.4279 in.) Oversize 0.25: 87.250-87.260 mm (3.4350-3.4354 in.) Reboring Limit: 0.25 mm (0.01 in.) max. Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)
5. Scored or scratched cylinder bores must be honed.
6. Check the top of the engine block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0.004 in.)
7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder bore for excessive wear. Piston-to-Cylinder Bore Clearance Standard (New): 0.020-0.040 mm (0.0008-0.0016 in.) Service Limit: 0.05 mm (0.002 in.)

See also:
• ENGINE REMOVAL
• PRESSURE PLATE AND CLUTCH DISC REMOVAL