See Figures 1, 2 and 3
The crankshaft main bearings on the Honda engines are retained by a large bridge type main bearing assembly. This is essentially one main bearing assembly. The 1988-91 1.6L (1590cc) engines use a main bearing cap and separate bridge assembly while the 1992-95 1.6L (1590cc and 1595cc) have returned to the one piece mainbearing cap/bridge design (see illustrations). The removal procedures are the same for both.
REMOVAL & INSTALLATION
- Remove the engine from the vehicle and place it on a work stand.
- Remove the crankshaft pulley attaching bolts and washer.
- Remove the front cover and the air conditioning idler pulley assembly, if so equipped. Remove cover assembly.
- Check the timing belt deflection. Remove the timing belt and sprockets.
- Invert the engine on work stand. Remove the flywheel and the rear seal cover. Remove the oil pan and gasket. Remove the oil pump inlet and the oil pump assembly.
- Ensure all bearing caps (main and connecting rod) are marked so they can be installed in their original positions. Turn the crankshaft until the connecting rod from which cap is being removed is up. Remove the connecting rod cap. Push the connecting rod and piston assembly up in the cylinder. Repeat the procedure for the remaining connecting rod assemblies.
- Remove the main bearing caps.
If the bearings are to be reused they should be identified to ensure that they are installed in their original position. Take care while aranging parts that must go back in a certain order. There is no way of determining which is the right piece if you mix them up.
- Carefully lift crankshaft out of block so upper thrust bearing surfaces are not damaged.
- Remove the main bearing inserts from the block and bearing caps.
- Remove the connecting rod bearing inserts from connecting rods and caps.
- Install a new rear oil seal in rear seal cover.
- Apply a thin coat of Polyethylene Grease to the rear crankshaft surface. Do not apply sealer to the area forward of oil sealer groove. Inspect all the machined surfaces on the crankshaft for nicks, scratches or scores which could cause premature bearing wear.
- If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize bearings. Ensure the bearing inserts and bearing bores are clean. Foreign material under the inserts will distort the bearing and cause a failure.
- Place the upper main bearing inserts in position in the bores with the tang fitted in the slot provided.
- Install the lower main bearings inserts in the bearing caps.
- Carefully lower the crankshaft into place.
- Check the clearance of each main bearing. Select fit the bearings for proper clearance.
- After the bearings have been fitted, apply a thin coat of heavy SAE 50 weight engine oil to journals and bearings. Install all the bearing caps.
The main bearing caps must be installed in their original positions.
- Align the upper thrust bearing.
- Check the crankshaft end-play.
- If the end-play exceeds specification, replace the upper thrust bearing. If the end-play is less than the specification, inspect the thrust bearing faces for damage, dirt or improper alignment. Install the thrust bearing and align the faces. Check the end-play.
- Install the new bearing inserts in the connecting rods and caps. Check the clearance of each bearing.
- If the bearing clearances are to specification, apply a thin coat of heavy SAE 50 weight engine oil to the journals and bearings.
- Turn the crankshaft throw to the bottom of the stroke. Push the piston all the way down until the rod bearings seat on the crankshaft journal.
- Install the connecting rod cap.
- After the piston and connecting rod assemblies have been installed, check the connecting rod crankshaft journal.
- Turn the engine on the work stand so the front end is up. Install the timing belt, sprockets, front cover, oil seal and the crankshaft pulley.
- Clean the oil pan, oil pump and the oil pump screen assembly.
- Prime the oil pump by filling the inlet opening with oil and rotating the pump shaft until oil emerges from the outlet opening. Install the oil pump.
- Position the flywheel on the crankshaft. Install the attaching bolts. Tighten to specification.
On the flywheel (manual transaxle only) locate clutch disc and install pressure plate.
- Turn the engine on the work stand so the engine is in the normal upright position. Install the oil level dipstick. Install the accessory drive pulley, if so equipped. Install and adjust the drive belt and the accessory belts to specification.
- Install either the clutch assembly or the torque converter.
- Install the oil pan.
- Remove the engine from work stand. Install the engine in the vehicle.
CLEANING AND INSPECTION BEARING OIL CLEARANCE
See Figures 4, 5, 6, 7 and 8
Remove cap from the bearing to be checked. Using a clean, dry rag, thoroughly clean all oil from crankshaft journal and bearing insert.
Plastigage® is soluble in oil, therefore, oil on the journal or bearing could result in erroneous readings.
Place a piece of Plastigage® along the full width of the bearing insert, reinstall cap, and tighten to specifications.
Torque specifications are given in the engine specifications earlier in this section.
Remove bearing cap, and determine bearing clearance by comparing width of Plastigage® to the scale on Plastigage® envelope. Journal taper is determined by comparing width of the bearing insert, reinstall cap, and tighten to specifications.
Do not rotate crankshaft with Plastigage® installed. If bearing insert and journal appear intact, and are within tolerances, no further main bearing service is required. If bearing or journal appear defective, cause of failure should be determined before replacement.
CRANKSHAFT END-PLAY/CONNECTING ROD SIDE PLAY
Place a prybar between a main bearing cap and crankshaft casting taking care not to damage any journals. Pry backward and forward, measure the distance between the thrust bearing and crankshaft with a feeler gauge. Compare the reading with specifications. If too great a clearance is determined, a main bearing with a larger thrust surface or crank machining may be required. Check with an automotive machine shop for their advice.
Connecting rod clearance between the rod and crankthrow casting can be checked with a feeler gauge. Pry the rod carefully on one side as far as possible and measure the distance on the other side of the rod.
If a journal is damaged on the crankshaft, repair is possible by having the crankshaft machined to a standard undersize.
In most cases, however, since the engine must be removed from the car and disassembled, some thought should be given to replacing the damaged crankshaft with a reground shaft kit. A reground crankshaft kit contains the necessary main and rod bearings for installation. The shaft has been ground and polished to undersize specifications and will usually hold up well if installed correctly.