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Engine Block: Removal & Installation Honda Fit I

Mechanical 35 illustrations ~1862 words

Piston, Pin, and Connecting Rod Replacement

Special Tools Required

  1. Piston base 07973-6570500
  2. Piston base spring 07973-6570600
  3. Piston pin base insert 07973-6890400
  4. Piston base head 07PAF-0010400
  5. Pilot collar 07973-6890300
  6. Adjustable piston pin driver shaft 07973-6890200
  7. Adjustable piston pin driver head 07973-6570201
  8. Piston base head insert (2) 07PAF-0010500

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Scheme 224: Disassembly
Scheme 224: Disassembly

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Scheme 227
  1. Assemble the special tool as shown.
  2. Temporarily install the pilot collar over the piston pin base insert (A), and adjust the piston base head inserts as shown, then tighten the screws (B). Remove the pilot collar.
  3. Assemble and adjust the length of the piston pin driver head and shaft to 57 mm (2.2 in.).
  4. With the arrow on top of the piston pointing up, place the piston assembly (A) on the special tool (B). Be sure you position the recessed flat area of the piston against the piston base head inserts (C) as shown.
  5. Press the pin (D) out with the pin driver (E), the pilot collar (F), and a hydraulic press.

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Scheme 228: Inspection
Scheme 228: Inspection

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Scheme 231
  1. Measure the diameter of the piston pin. NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. Piston Pin Diameter Standard (New): 17.996-18.000 mm (0.7085-0.7087 in.)
  2. Zero the dial indicator to the piston pin diameter.
  3. Check the difference between the piston pin diameter and the piston pin hole diameter on the piston. Piston Pin-to-Piston Clearance Standard (New): 0.010-0.018 mm (0.0004-0.0007 in.)
  4. Check the difference between the piston pin diameter and the connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.020-0.036 mm (0.0008-0.0014 in.)

Scheme 232

Scheme 232: Reassembly
Scheme 232: Reassembly

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Scheme 233
  1. Assemble the piston with the arrow (A) pointing up and the connecting rod with the embossed marks (B) on the same side.
  2. Insert the pilot collar (A) into the piston and the connecting rod.
  3. With the arrow on top of the piston and the embossed mark on the connecting rod facing up, place the piston assembly (B) on the special tool (C). Be sure you position the recessed flat area of the piston against the piston base head inserts (D) as shown.
  4. Press the pin (E) in with the pin driver (F) and a hydraulic press.

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Scheme 234: Piston Ring Replacement
Scheme 234: Piston Ring Replacement

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  1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-291421-S33744286702008072800000) ).
  2. Using a ring expander (A), remove the old piston rings (B).
  3. Clean all the ring grooves thoroughly with a squared-off broken ring;-bra ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top ring grooves are 1.0 mm (0.04 in.) wide 1, the second ring groove is 1.2 mm (0.05 in.) wide, and the oil ring groove is 2.0 mm (0.08 in.) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool. 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 «BLOCK AND PISTON INSPECTION»(ref-291421-S34963277152008072800000) ). If the bore is over the service limit, the engine block must be rebored. Piston Ring End-Gap Top Ring: Standard (New): 0.15-0.30 mm (0.006-0.012 in.) Service Limit: 0.60 mm (0.024 in.) Second Ring: Standard (New): 0.35-0.50 mm (0.014-0.020 in.) Service Limit: 0.65 mm (0.026 in.) Oil 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 R1 mark and the second ring (B) has a R mark. The manufacturing marks (C) must face up. Piston Ring Dimensions
  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) : 0.065-0.090 mm (0.0026-0.0035 in.) Service Limit: 0.15 mm (0.006 in.) Second Ring Clearance Standard (New) : 0.030-0.055 mm (0.0012-0.0022 in.) Service Limit: 0.13 mm (0.005 in.)

Scheme 240

Scheme 240: If the crankshaft is already installed
Scheme 240: If the crankshaft is already installed

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Scheme 241
  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 timing 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 «CONNECTING ROD BEARING REPLACEMENT»(ref-291421-S33470628422008072800000) ).
  7. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-291421-S42133315012008072800000) ).
  8. Apply new engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) +90°.

Scheme 242

Scheme 242: If the crankshaft is not installed
Scheme 242: If the crankshaft is not installed

Scheme 243

Scheme 243
Scheme 243
  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 timing 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 244

Scheme 244: Connecting Rod Bolt Inspection
Scheme 244: Connecting Rod Bolt Inspection
  1. Measure the diameter of each connecting rod bolt at point A and point B with a micrometer.
  2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.05 mm (0-0.002 in.)
  3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

Crankshaft Installation

Special Tools Required

  1. Handle driver 07749-0010000
  2. Oil seal driver attachment 07ZAD-PNAA100

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  1. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-291421-S33470628422008072800000) ).
  2. Check the main bearing clearance with plastigage (see «MAIN BEARING CLEARANCE INSPECTION»(ref-291421-S16128395362008072800000) ).
  3. Install the bearing halves in the engine block and connecting rods.
  4. Apply a coat of new engine oil to the main bearings and rod bearings.
  5. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the engine block.
  6. Install the thrust washers (A) in the No. 4 journal of the engine block.
  7. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-291421-S42133315012008072800000) ).
  8. Apply new engine oil to the threads and flange of the connecting rod bolts.
  9. Seating 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 install the caps and bolts finger-tight.
  10. 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 cap, then install the caps and bolts finger-tight.
  11. Tighten the connecting rod bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf-ft).
  12. Tighten the connecting rod bolts an additional 90°. NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 7 of the procedure. Do not loosen it back to the specified angle.
  13. Remove old liquid gasket from the bearing cap bridge mating surfaces.
  14. Clean and dry the bearing cap bridge mating surfaces.
  15. Apply a 1.5 mm wide bead of the liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, along the broken lines (A). Install the component within 5 minutes of applying the liquid gasket. NOTE: If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
  16. Put the bearing cap bridge on the engine block.
  17. Apply new engine oil to the threads and flange of the bearing cap bolts.
  18. Tighten the bearing cap bolts in sequence to 25 N.m (2.5 kgf.m, 18 lbf.ft).
  19. Tighten the bearing cap bolts an additional 40°.
  20. Clean the excess liquid gasket off the engine block.
  21. Use the handle driver and oil seal driver attachment to drive a new oil seal squarely into the engine block to the specified installed height.
  22. Measure the distance between the crankshaft and oil seal. Oil Seal Installed Height: 7-8 mm (0.28-0.31 in.)
  23. Install the dowel pins (A) and new O-ring (B) on the oil pump (C), then align the inner rotor with crankshaft, and install the oil pump.
  24. Install the oil screen (D) with new gasket (E).
  25. Install the cylinder head (see «CYLINDER HEAD INSTALLATION»(ref-291404-S09912006922008072800000) ).
  26. Install the cam chain (see «CAM CHAIN INSTALLATION»(ref-291404-S21397526282008072800000) ).
  27. M/T model: install the flywheel (see «FLYWHEEL REPLACEMENT»(ref-291412-S23781756972008072800000) ), clutch disc (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291412-S04079287502008072800000) ), and pressure plate (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291412-S04079287502008072800000) ).
  28. A/T model: Install the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-291388-S15352497282008072800000) ).
  29. Install the transmission: Manual transmission (see «TRANSMISSION INSTALLATION»(ref-291396-S05849523232008072800000) ) Automatic transmission (see «TRANSMISSION INSTALLATION»(ref-291388-S06469121292008072800000) )
  30. Install the engine assembly (see «ENGINE INSTALLATION»(ref-291418-S20688680672008072800000) ). NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idle speed until it reaches normal operating temperature, then continue running it for about 15 minutes.

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Scheme 252: Oil Pan Installation
Scheme 252: Oil Pan Installation

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  1. Remove old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.
  2. Clean and dry the oil pan mating surfaces.
  3. Install the new oil pan gasket on the oil pan.
  4. Apply liquid gasket, P/N 08718-0001 or 08718-0009, to the engine block mating surface of the oil pan. Install the component within 5 minutes of applying the liquid gasket. NOTE: Apply a 1.5 mm wide bead of the liquid gasket along the broken line (A). Apply a 5.0 mm wide bead of the liquid gasket to the shaded area (B). If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
  5. Install the oil pan (A) with dowel pin (B) and new O-ring(C).
  6. Tighten the bolts in three steps. NOTE: Wait at least 30 minutes to allow liquid gasket to cure before filling the engine with oil. Do not run the engine for at least 3 hours after installing the oil pan.
  7. Install the clutch cover/torque converter cover (A), and tighten the bolts (B) securing the transmission. M/T model A/T model
  8. Install the dipstick tube (A) with new O-ring (B).
  9. M/T model: Install the heat shield (see step 7 on «DRIVESHAFT INSTALLATION»(ref-291394-S08409824922008072800000) ).

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