Engine Block: Removal & Installation Honda Insight ZE2 рестайлинг

Piston, Pin, and Connecting Rod Replacement

Special Tools Required

1. Piston Base Head 07PAF-0010400
2. Piston Base Head Insert 07PAF-0010500
3. Insert Pin 07PAF-0010700
4. Pilot Pin 070AF-PWC0110
5. Insert Adjust 070AF-PWC0120
6. Pilot Collar, O.D. 18 mm 070AF-PWC0130
7. Piston Base 07973-6570500
8. Piston Base Spring 07973-6570600

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1. Assemble the special tool as shown.
2. Temporarily install the pilot collar, O. D. 18 mm over the pilot pin (A), and adjust the piston base head insert as shown, then tighten the screws (B). Remove the pilot collar.
3. Assemble and adjust the length of the insert pin and the insert adjust to 57 mm (2.2 in).
4. With the arrow on top of the piston pointing up, place the piston assembly (A) on the piston base head (B). Be sure you position the recessed flat area of the piston against the piston base head insert (C) as shown.
5. Press the pin (D) out with the insert pin and the insert adjust (E), the pilot collar (F), and a hydraulic press.

Piston Installation

If the Crankshaft is Already Installed

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1. Set the crankshaft to bottom dead center (BDC) for each cylinder as its piston is installed.
2. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.
3. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine block.
4. Position the piston/connecting rod assembly 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-rod journal alignment before pushing the piston into place.
6. Check the connecting rod bearing clearance with a plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-513183-S37320365152012110700000) ).
7. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-513183-S42545360752012110700000) ).
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).
9. 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.

If the Crankshaft is Not Installed

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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. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.
3. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine block.
4. Position the piston/connecting rod assembly 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. Position all pistons at top dead center (TDC).

Scheme 245

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. Driver Handle, 15 x 135L 07749-0010000
2. Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

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1. Check the main bearing clearance with a plastigage (see «MAIN BEARING CLEARANCE INSPECTION»(ref-513183-S26738682532012110700000) ).
2. Check the connecting rod bearing clearance with a plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-513183-S37320365152012110700000) ).
3. Install the bearing halves in the engine block and the connecting rods.
4. Apply new engine oil to the main bearings and the rod bearings.
5. Install the CKP pulse plate (A) on the crankshaft (B); face the marked side (C) toward the transmission, and align the tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
6. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the engine block.
7. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 4 journal.
8. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-513183-S42545360752012110700000) ).
9. Apply new engine oil to the threads and flanges of the connecting rod bolts.
10. Seat the rod journals into connecting rod No. 1 and the connecting rod No. 4. Line up the mark (A) on the connecting rod and cap, then install the caps and the bolts finger-tight.
11. 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 the cap, then install the caps and the bolts finger-tight.
12. Torque the connecting rod bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft).
13. 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 8 of the procedure. Do not loosen it back to the specified angle.
14. Remove all of the old liquid gasket from the bearing cap bridge mating surfaces the bolts, and the bolt holes.
15. Clean and dry the bearing cap bridge mating surfaces.
16. Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the engine block mating surface of the bearing cap bridge. Install the component within 5 minutes of applying the liquid gasket. NOTE: Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A). 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.
17. Put the bearing cap bridge on the engine block.
18. Apply new engine oil to the threads of the bearing cap bolts.
19. Torque the bearing cap bolts in sequence to 25 N.m (2.5 kgf.m, 18 lbf.ft).
20. Tighten the bearing cap bolts an additional 40'
21. Clean the excess liquid gasket off the engine block.
22. Clean and dry the crankshaft oil seal housing.
23. Apply a light coat of new engine oil to the lip of the crankshaft oil seal.
24. Use the driver handle, 15 x 135L, and the oil seal driver attachment, 96 mm, to drive a new crankshaft oil seal squarely into the block to the specified installed height.
25. Measure the distance between the cylinder block (A) and the oil seal (B). Oil Seal Installed Height: 0.2-1.2 mm (0.008-0.047 in)
26. Install the cylinder head (see «ROCKER ARM ASSEMBLY INSTALLATION»(ref-513166-S32560243292012110700000) ).
27. Install the oil pump (A) with a new O-ring (B).
28. Install the oil screen (C) with a new gasket (D).
29. Install the oil pan (see «OIL PAN INSTALLATION»(ref-513183-S37349971752012110700000) ).
30. Install the cam chain (see «CAM CHAIN INSTALLATION»(ref-513166-S39804079872012110700000) ).
31. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
32. Install the harness cover (C).
33. Install the IMA motor rotor position sensor (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ), the IMA motor housing (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ), and the IMA motor rotor (see «IMA MOTOR ROTOR REMOVAL/INSTALLATION»(ref-513150-S28757816692012110700000) ).
34. Install the transmission (see «TRANSMISSION INSTALLATION»(ref-513160-S29137252232012110700000) ).
35. Install the engine/IMA motor/transmission assembly (see «ENGINE INSTALLATION»(ref-513178-S03234337072012110700000) ). NOTE: When any crankshaft or connecting rod bearing is replaced, run the engine at idle until it reaches normal operating temperature, then continue to run it for about 15 minutes.

Scheme 257

1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-513183-S00942600622012110700000) ).
2. Remove the CKP pulse plate (A). NOTE: Be careful not to damage the journals and the CKP pulse plate.
3. Install the CKP pulse plate on the crankshaft (B); face the marked side (C) toward the transmission, and align the tab (D) on the CKP pulse plate with the groove (E) on the crankshaft.
4. Install the crankshaft (see «CRANKSHAFT INSTALLATION»(ref-513183-S13953782932012110700000) ).

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1. Remove all of the old liquid gasket from the oil pan mating surfaces, the bolts, and the bolt holes.
2. Clean and dry the oil pan mating surfaces and the O-ring groove.
3. Install the new oil pan gasket (A), the new O-ring (B), and the dowel pins (C) on the oil pan.
4. Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the engine block mating surface of the oil pan and to the inside edge of the bolt holes. Install the component within 5 minutes of applying the liquid gasket. NOTE: Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A). Apply a 5.0 mm (0.197 in) diameter bead of liquid gasket to the shaded area (B). Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket to the broken line (C). 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. NOTE: Raise the oil pan carefully so as not to damage the IMA motor rotor position sensor. Wait at least 30 minutes before filling the engine with oil. Do not run the engine for at least 3 hours after installing the oil pan. Make sure to install the bolts in the correct locations according to size.
6. Tighten the bolts in three steps. Wipe off the excess liquid gasket from crankshaft pulley end and the drive plate end.
7. Install the transmission mounting bolts.
8. Connect the CKP sensor connector (A), then install the CKP sensor cover (B).
9. Install the dipstick tube (A) with a new O-ring (B), then install the dipstick.
10. If the engine is still in the vehicle, do steps 11 through 15 .
11. Install the A/C compressor (see step 32 on «ENGINE INSTALLATION»(ref-513178-S03234337072012110700000) ).
12. Install the driveshaft heat shield (see step 27 on «ENGINE INSTALLATION»(ref-513178-S03234337072012110700000) ).
13. Install the drive belt (see «DRIVE BELT REPLACEMENT»(ref-513159-S05522561372012110700000) ).
14. Install the splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-513179-S41212899722012110700000) ).
15. Refill the engine with engine oil (see step 6 on «ENGINE OIL REPLACEMENT»(ref-513154-S30056503812012110700000) ).

Transmission End Crankshaft Oil Seal Installation - In Car

Special Tools Required

1. Driver Handle, 15 x 135L 07749-0010000
2. Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

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1. Remove the transmission (see «TRANSMISSION REMOVAL»(ref-513160-S19092007002012110700000) ).
2. Remove the IMA motor rotor (see «IMA MOTOR ROTOR REMOVAL/INSTALLATION»(ref-513150-S28757816692012110700000) ), the IMA motor housing (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ), and the IMA motor rotor position sensor (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ).
3. Clean and dry the crankshaft oil seal housing.
4. Apply a light coat of new engine oil of the crankshaft oil seal.
5. Use the driver handle, 15 x 135L, and the oil seal driver attachment, 96 mm, to drive a new crankshaft oil seal squarely into the block to the specified installed height.
6. Measure the distance between the cylinder block (A) and the oil seal (B). Oil Seal Installed Height: 0.2-1.2 mm (0.008-0.047 in)
7. Install the IMA motor rotor position sensor (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ), the IMA motor housing (see «IMA MOTOR HOUSING REMOVAL/INSTALLATION»(ref-513150-S22101359612012110700000) ), and the IMA motor rotor (see «IMA MOTOR ROTOR REMOVAL/INSTALLATION»(ref-513150-S28757816692012110700000) ).
8. Install the transmission (see «TRANSMISSION INSTALLATION»(ref-513160-S29137252232012110700000) ).

Drain Bolt/Sealing Bolt Installation

Note. When installing the drain bolt and/or sealing bolt, always use a new washer.

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1. Remove the block cover (A).
2. Install the block cover in the reverse order of removal.