Engine Block: Diagnosis Honda Insight ZE2

Crankshaft Inspection

Out-of-Round and Taper

Scheme 196

Scheme 197

1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ).
2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
3. Clean the keyway slot and threaded holes for damage.
4. Measure the out-of-round at the middle of each rod and the 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 the taper at the edges of each rod and the 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) Straightness
6. Place the engine block on a flat surface, crankshaft side up.
7. Clean and install the bearings on the No. 1 and No. 5 journals of the engine block.
8. Lower the crankshaft into the engine block.
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: 0.040 mm (0.0016 in)

Scheme 198

Scheme 199

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Scheme 201

1. Remove the crankshaft and the pistons (see «CRANKSHAFT AND PISTON REMOVAL»(ref-360295-S38251644852010042800000) ).
2. Check the piston for distortion or cracks.
3. Measure the piston skirt diameter (A) at a point 16 mm (0.6 in) from the bottom of the skirt. Piston Diameter Standard (New): 72.969-72.979 mm (2.8728-2.8732 in) Service Limit: 72.967 mm (2.8727 in) Oversize Piston Diameter 0.25: 73.219-73.229 mm (2.8826-2.8830 in)
4. Measure wear and taper in direction 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): 73.000-73.015 mm (2.8740-2.8746 in) Service Limit: 73.065 mm (2.8766 in) Oversize 0.25: 73.250-73.265 mm (2.8839-2.8844 in) Reboring limit: 0.25 mm (0.010 in) max. Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.002 in)
5. Hone any scored or scratched cylinder bores.
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 the engine block for excessive wear. Piston-to-Cylinder Clearance Standard (New): 0.021-0.046 mm (0.0008-0.0018 in) Service Limit: 0.05 mm (0.002 in)