Engine Block: Diagnosis Honda Insight ZE2 рестайлинг

Crankshaft Inspection

Out-of-Round and Taper

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1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-513183-S00942600622012110700000) ).
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 (0.00020 in) max. Service Limit: 0.010 mm (0.00039 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 (0.00020 in) max. Service Limit: 0.010 mm (0.00039 in) Straightness
6. Place the V-blocks on a flat surface.
7. Check the total runout with the crankshaft supported on V-blocks.
8. 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 the pistons (see «CRANKSHAFT AND PISTON REMOVAL»(ref-513183-S00942600622012110700000) ).
2. Check the piston for distortion or cracks.
3. Measure the piston skirt diameter (A) at a point 16 mm (0.63 in) from the bottom of the skirt. Piston Diameter Standard (New): 72.969-72.979 mm (2.87279-2.87318 in) Service Limit: 72.967 mm (2.87271 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 (2.87401-2.87460 in) Service Limit: 73.065 mm (2.87657 in) Oversize 0.25: 73.250-73.265 mm (2.8839-2.8844 in) Reboring limit: 0.25 mm (0.0098 in) max. Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.0020 in)
5. Scored or scratched cylinder bore 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 (0.002 in) max.
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 (0.00083-0.00181 in) Service Limit: 0.05 mm (0.0020 in)

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1. Measure the cylinder bores (see «BLOCK AND PISTON INSPECTION»(ref-513183-S19046833622012110700000) ). If the engine block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bore must be honed.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree Crosshatch pattern (A). NOTE: Use only a rigid hone with 400 grit or finer stone, such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or broken.
3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. NOTE: Never use solvent, it will only redistribute the grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the engine block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

Inspection

Note. Inspect the piston, the piston pin, and the 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): 17.996-18.000 mm (0.70850-0.70866 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 in the piston. Piston Pin-to-Piston Clearance Standard (New): 0.010-0.017 mm (0.00039-0.00067 in)
4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.019-0.036 mm (0.00075-0.00142 in)

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1. Assemble the piston and the connecting rod with the arrow (A) and the embossed mark (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 piston base head (C). Be sure you position the recessed flat area of the piston against the area of the piston base head insert (D) as shown.
4. Press the pin (E) in with the insert pin and the insert adjust (F) and a hydraulic press.

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1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-513183-S00942600622012110700000) ).
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, or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top and second ring grooves are 1.0 mm (0.04 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-513183-S19046833622012110700000) ). 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 (0.006-0.011 in) Service Limit: 0.60 mm (0.023 in) Second Ring: Standard (New): 0.30-0.42 mm (0.012-0.016 in) Service Limit: 0.65 mm (0.025 in) Oil Ring: Standard (New): 0.10-0.40 mm (0.004-0.015 in) Service Limit: 0.80 mm (0.031 in)
6. Install the rings as shown. The top ring (A) has a RC mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must face upward.
7. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance Standard (New): 0.065-0.090 mm (0.003-0.003 in) Service Limit: 0.15 mm (0.005 in) Second Ring Clearance Standard (New): 0.030-0.055 mm (0.002-0.002 in) Service Limit: 0.12 mm (0.004 in)
8. Rotate the rings in their grooves to make sure they do not bind.
9. Position the ring end gaps as shown