Honda Civic Service Manual: Connecting Rod and Crankshaft End Play Inspection (K24Z7)

1.

Remove the engine wire harness.

1.

Remove the intermediate shaft.

1.

Remove the clutch case cover and the transmission mounting bolts.

1.

Remove the transmission.

1.

Install the ring gear holder.

2.

Install the clutch alignment shaft and the remover handle.

3.

To prevent warping, loosen the pressure plate mounting bolts (A) in a crisscross pattern in several steps.

4.

Remove the pressure plate (B).

1.

Remove the clutch disc (A), the clutch alignment shaft, and the remover handle.

1.

Remove the flywheel (A).

NOTE: Loosen the flywheel mounting bolts (B) in a crisscross pattern in several steps.

2.

Remove the ring gear holder.

1.

Remove the rail with the fuel injector.

1.

Remove the intake manifold with the throttle body.

1.

Remove the injector base (A).

1.

Remove the A/F sensor.

1.

Remove the exhaust chamber cover.

2.

Remove the WU-TWC.

1.

Remove the alternator.

1.

Remove the water passage.

1.

Remove the starter.

1.

Remove the ignition coil cover.

1.

Remove the ignition coils.

1.

Remove the cylinder head cover.

1.

Turn the crankshaft so its white mark (A) lines up with the pointer (B).

NOTE: The other pointer (C) is not used.

1.

Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

1.

Remove the harness clamp.

1.

Remove the ground cable (A).

2.

Remove the VTC oil control solenoid valve (B).

1.

Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

2.

Remove the bolt with a socket, 19 mm (C) and a breaker bar, then remove the crankshaft pulley.

1.

Remove the side engine mount bracket.

1.

Remove the cam chain case (A) and the spacer (B).

1.

Loosely install the crankshaft pulley.

2.

Turn the crankshaft counterclockwise to compress the auto-tensioner.

3.

Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.

4.

Remove the auto-tensioner.

1.

Remove cam chain guide B.

2.

Remove cam chain guide A and the tensioner arm (B).

1.

Remove the cam chain.

1.

Loosen the rocker arm and the adjusting screws (A).

2.

Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.

3.

Remove cam chain guide B , the camshaft holders (A).

1.

Remove the camshafts (A).

1.

Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

1.

Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

2.

Remove the cylinder head.

1.

Remove the bolts securing the oil pan.

2.

Using a flat blade screwdriver, separate the oil pan from the engine block in the places shown.

3.

Remove the oil pan.

1.

Loosely install the crankshaft pulley.

2.

To hold the rear balancer shaft, insert a 6 mm long pin punch (A) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.

3.

Turn the crankshaft counterclockwise to compress the oil pump chain auto-tensioner.

4.

Remove the crankshaft pulley.

5.

Align the holes on the lock (A) and the oil pump chain auto-tensioner (B), then insert a 3.0 mm (7/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

6.

Use a transmission jack to lift the transmission 30－40 mm (1.18－1.57 in), then remove the oil pump chain auto-tensioner.

1.

Loosen the oil pump sprocket mounting bolt.

2.

Remove the oil pump sprocket (A) and the oil pump chain guide (B).

3.

Remove the oil pump chain.

4.

Remove the oil pump.

1.

Remove the baffle plate.

1.

Install the baffle plate.

1.

Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

2.

Install the oil pump chain on the crankshaft sprocket with the colored link plate (A) aligned with the TDC mark (B) on the crankshaft sprocket.

3.

Set the oil pump chain on the oil pump chain sprocket (A) with the punch mark (B) aligned with the center of the two colored link plates (C), then install the oil pump chain sprocket to the oil pump.

4.

To hold the rear balancer shaft, insert a 6 mm long pin punch (D) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.

5.

Apply new engine oil to the threads of the oil pump sprocket mounting bolt (E), then install the oil pump sprocket mounting bolt and the oil pump chain guide (F).

6.

Remove the 6 mm long pin punch.

7.

Turn the plate (A) counterclockwise, to release the lock, then push the oil pump chain auto-tensioner arm (B), and set the first cam (C) to the first edge of the rack (D). Insert a 3.0 mm (7/64 in) diameter pin (E) into the hole (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will become damaged.

1.

Install the oil pump chain tensioner.

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.

3.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pan and to the inner threads of the bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

4.

Install the oil pan on the engine block.

5.

Tighten the bolts in three steps. In the final step, torque all bolts, in sequence, to 12 N·m (1.2 kgf·m, 9 lbf·ft). Wipe off the excess liquid gasket on the each side of crankshaft pulley and the flywheel/drive plate.

NOTE:

1.

Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

1.

Install a new coolant separator (A) in the engine block whenever the engine block is replaced.

2.

Clean the cylinder head and the engine block surface.

3.

Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.

4.

Install the cylinder head on the engine block.

5.

Measure the diameter of each cylinder head bolt at point A and point B.

6.

If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.

7.

Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.

8.

Torque the cylinder head bolts in sequence to 39 N·m (4.0 kgf·m, 29 lbf·ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.

9.

After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 8. If you are using a new cylinder head bolt, tighten the bolt an extra 90 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

1.

Clean and dry the No. 5 rocker shaft holder mating surface.

2.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the cylinder head mating surface of the No. 5 rocker shaft holder and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

3.

Install the lost motion assemblies (A) in the cylinder head.

NOTE: Apply new engine oil to the lost motion assembly.

4.

Insert the bolts (B) into the rocker shaft holder, then install the rocker arm assembly (C) on the cylinder head.

5.

Remove the bolts from the rocker shaft holder.

1.

Make sure the punch marks on the VTC actuator and the exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. Apply new engine oil to the camshaft journals and lobes.

1.

Set the camshaft holders (A) and cam chain guide B in place.

2.

Tighten the bolts to the specified torque.

1.

To hold the intake camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate A and through the No. 5 rocker shaft holder (D).

2.

To hold the exhaust camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate B and through the No. 5 rocker shaft holder (D).

3.

Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket.

4.

Install the cam chain on the VTC actuator and the exhaust camshaft sprocket with the punch marks (A) aligned with the center of the two colored link plates (B).

1.

Install cam chain guide A and the tensioner arm (B).

2.

Install cam chain guide B.

1.

Compress the auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.2 mm (3/64 in) diameter pin back into the holes (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.

2.

Install the auto-tensioner.

3.

Remove the pin from the auto-tensioner.

4.

Remove the camshaft lock pin set.

1.

Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.

2.

Remove the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.

3.

Clean and dry the chain case mating surfaces.

4.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the chain case and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

5.

Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the chain case, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

1.

Install the side engine mount bracket (A), then tighten the side engine mount bracket mounting bolts.

1.

Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). Lubricate with new engine oil as shown.

2.

Install the crankshaft pulley, and hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

3.

Torque the bolt to 50 N·m (5.1 kgf·m, 37 lbf·ft) with a torque wrench and a socket, 19mm(C). Do not use an impact wrench. If the pulley bolt or crankshaft are new, torque the bolt to 177 N·m (18.0 kgf·m, 131 lbf·ft), then remove the bolt and torque it to 50 N·m (5.1 kgf·m, 37 lbf·ft).

4.

Tighten the pulley bolt an additional 90 °.

1.

Install the VTC oil control solenoid valve (A) with a new O-ring (B).

NOTE:

2.

Install the ground cable (C).

1.

Install the harness clamp.

1.

Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

3.

Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No.1 cylinder, and slide it back and forth; you should feel a slight amount of drag.

4.

If you feel too much or too little drag, loosen the locknut with the locknut wrench and the adjuster, and turn the adjusting screw until the drag on the feeler gauge is correct.

5.

Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.

6.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

7.

Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.

8.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

9.

Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.

10.

Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

11.

Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.

1.

Check the spark plug seals for damage. If any seals are damaged, replace them.

2.

Thoroughly clean the head cover gasket and the groove.

NOTE: Check and, if necessary, replace the head cover gasket.

3.

Install the head cover gasket (A) in the groove of the cylinder head cover (B). Make sure the head cover gasket is seated securely.

4.

Remove all of the old liquid gasket from the chain case and the No.5 rocker shaft holder.

5.

Clean the head cover contacting surfaces with a shop towel.

6.

Apply liquid gasket, (P/N 08718-0004 or 08718-0009) on the chain case and the No. 5 rocker shaft holder mating areas (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

7.

Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.

8.

Inspect the spark plug seals for damage.

9.

Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.

10.

Tighten the bolts in two steps. In the final step torque bolts, in sequence, to 12 N·m (1.2 kgf·m, 9 lbf·ft).

NOTE:

1.

Install the ignition coils.

1.

Install the ignition coil cover.

1.

Install the starter.

1.

Install the water passage with new O-ring.

1.

Install the alternator.

1.

Install the WU-TWC with new gasket.

2.

Install the exhaust chamber cover.

1.

Install the A/F sensor.

1.

Install the injector base (A) with a new gasket (B).

1.

Install the intake manifold (A) with new gaskets (B), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.

1.

Install the rail with the fuel injector.

1.

Install the flywheel (A) on the crankshaft, and install the mounting bolts (B) finger-tight.

2.

Install the ring gear holder.

3.

Tighten the flywheel mounting bolts (A) in a crisscross pattern in several steps.

1.

Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.

2.

Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B).

NOTE: Wipe off any excess grease.

3.

Install the clutch disc using the clutch alignment shaft and the remover handle.

1.

Install the pressure plate (A) and the mounting bolts (B) finger-tight.

2.

Torque the pressure plate mounting bolts (A) in a crisscross pattern.

NOTE:

3.

Remove the ring gear holder.

4.

Remove the clutch alignment shaft and the remover handle.

5.

Make sure the diaphragm spring fingers are all the same height.

1.

Install the transmission.

1.

Install the clutch case cover and the transmission mounting bolts.

1.

Install the intermediate shaft into the differential correctly.

NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal.

1.

Install the engine wire harness.