2003 HONDA CIVIC Workshop Manual

Main Bearing Selection
Crankshaft Bore Code Location
1. Numbers or letters or bars have been stamped on
the end of the block as a code for the size of each of
the five main journal bores. Write down the crank
bore codes. lf you can't read the codes because of
accumulated dirt and dust, do not scrub them with
a wire brush or scraper. Clean them only with
solvent or detergent.
No. 1 JOURNALIPULLEY END}No. 5 JOURNAL{FLYWHEEL END)
Main Journal Code Location
2. The main journal codes a{e stamped on the
cra n kshaft.
No. 1 JOURNALNo. 5 JOURNAL
(cont'd)
7-7

Engine Block
Crankshaft Main Bearing
Replacement (cont'd)
3. Use the crank bore codes and crank journal codes
to select the appropriate replacement bearings
from the following table.
NOTE:. Color code is on the edge of the bearing.. When using bearing halves of different colors. it
does not matter which color is used in the top or
bottom.
Mainiournslcooe
Crank ---=-> Lalger crank bore
bore | 1or 2ot 3or c oi__-lcode IAorl Borll Corlll Dortttt I-- --> Smaller bearing {Thickerl
(Thicker)
1
2
4
5
Pink f!1f;* v"rro* c,""n
ll
f111f;,," v"no* c,""" $;;fl
cr""n $ffi ero-n
ffi#Tr,.*" i.,""*Creen ; g=jiff;i Brown Black
;;lT]*
'---l-'o"*,
Brown Black 6il;
Brack !l;kr ar*
7-8
Connecting Rod Bearing
Replacement
Rod Bearing Clearance lnspection
1. Remove the oil pump (see page 8-9).
2. Bemove the baffle plates (see step 6 on page 7-12).
3. Remove the connecting rod cap and bearing half.
4. Clean the crankshaft rod journal andbearinghalf
with a clean shop towel.
5. Place plastigage across the rod journal.
6. Reinstallthe bearing half and cap, and torque the
bolts to 20 N.m (2.0 kgf.m, 14lbf.ft) -l 90 ".
NOTE: Do not rotate the crankshaft during
inspection.
7. Remove the rod cap and bearing half, and measure
the widest part of the plastigage.
Connecting Rod Bearing-to-Journal Oil
Clearance:
Standard {Newl: 0.020 0.050 mm(0.0008 --0.0020 in.l
Service Limit: 0.060 mm (0.0024 in.)
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8.
9.
lf the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new,
complete bearing with the same color code(s), and
recheck the clearance. Do not file. shim, or scrape
the bearings or the caps to adjust clearance.
lf the plastigage shows the clearance is still
incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance agaln. lf the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearing, replace the crankshaft and stan over.
Rod Bearing Selection
1. Inspect each connecting rod for cracks and heat
damage.
Connecting Rod Big End Eore Code Locations
2. Each rod has a tolerance range from 0 0.024 mm
(0.0009 in.), in 0.006 mm (0.0002 in.) increments,
depending on the size of its big end bore. lt's then
stamped with a number or bar (1, 2,3 or 4/1, ll,lll, ol
llll) indicating the range. You may find any
combination of numbers and bars in any engine.(Half the number or bar is stamped on the bearing
cap, the other half on the rod.)
lf you can't read the code because of an
accumulation of oil and varnish. do not scrub it
with a wire brush or scraper. Clean it only with
solvent or detergent.
Normal Bore Size: 48.0 mm 11.89 in.l
(cont'd)
7-9

Engine Block
Connecting Rod Bearing Replacement (cont'dl
Connecting Rod Journal Code Location
3. The connecting rod journalcodes are stamped on
the crankshaft.
Connecting Rod Journal Code Location (Letters or
Bars)
No.l JOURNAL No. 4 JOURNAL
7-10
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4. Use the big end bore codes and rod journalcodes
to select appropriate replacement bearings from
the following table.
NOTE:. Color code is on the edge of the bearing.. When using bearing halves of different colors, it
does not matter which color is used in the top or
bottom.
Big end ----------> Larger big end boreborecodolorl2oJll3 ol lll4 orllll
---------> Smallsrb.aring {Thickerl
PinkPink/YellowYollow/GrecnGreen
YellowYellow/GreenGreen/BrownBrown
GreenGreen/BrownErown/BlackBlack
BrownBrown/BlackBlack/BlueBlue
Rod
B
c
D
{\
(Thicker)
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1.
OilPan Removal
Drain the engine oil (see page 8-5).
lf the engine is still in the vehicle, remove the
subframe.
-1 Attach the chain hoist to the engine (see step
35 on page 5-6).-2 Disconnectthe suspension lower arm balljoints (see step 3 on page 18-19).-3 Remove the rear mounl mounting bolts (see
step 39 on page 5-7).-4 Remove the front mount mounting bolt (see
step 40 on page 5-7).-5 Use a marker to make alignment marks on the
reference lines that align with the centers of
the rear subframe mounting bolts. Remove the
front subframe (see step 43 on page 5-8).
Remove the bolts/nuts securing the oil pan.
Drive an oil pan seal cutter between the oil pan and
cylinder block.
5. Cut the oil panseal bystrikingthesideofthecutter
to slide the cutter along the oil pan.
6. Remove the oil pan.
7-11

Engine Block
Crankshaft and Piston Removal
1. Remove the engine assembly (see page 5-2).
2. Remove the transmission (see page 13-4).
3. Remove the oil pan (see page 7-1 1).
4. Remove the oil pump {see page 8-9).
5. Remove the cylinder head (see page 6-23).
6. Remove the baffle plates.
7. Remove the 8 mm bolts.
E
7-12
8. Remove the bearing cap bolts. To prevent warpage,
unscrew the bolts in sequence 1/3 turn at a time:
repeat the sequence until all bolts are loosened.
Remove the lower block and bearings, Keep all
bearings in order.
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10.Remove the rod caps/bearings. Keep all caps/
bearings in order.
Liftthe crankshaft out ofthe engine, being careful
not to damage the journals.
Remove the upper bearing halves from the
connecting rods. and set them aside with their
respective caps.
lf you can feel a ridge of metal or hard carbon
around the top of each cylinder, remove it with a
ridge reamer {A). Followthe reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they are pushed out.
11.
t.J.
14. Use the wooden handle of a hammer (A) to drive
out the pistons (B).
Reinstall the lower block and bearings on the
engine in the proper order,
Reinstallthe connecting rod bearings and caps
after removing each piston/connecting rod
assembly.
To avoid mixup on reassembly. mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it
indicates the rod bore size.
15.
to.
17.
7-13

Engine Block
Crankshaft lnspection
Out-ol-Round and Taper
1. Remove the crankshaft from the cylinder block (see
page 7-121.
2. Clean the crankshaft oil passages with pipe
cleaners or a suitable brush.
3. Clean the keyway and threads.
4. Measure out-of round at the middle of each rod and
main journal in two places. The difference between
measurements on each journal must not be more
than the service Iimit.
Journal Out-ot-Round
Standard (New): 0.005 mm (0.0002 in.) max.
Service Limit; 0.010 mm (0.0004 in.)
5. Measure taper at the edges of each rod and mainjournal. The difference between measurements on
each journal must not be more than the service
limit.
JournalTaper
Standard lNewl: 0.005 mm (0.0002 in.) max.
Service Limit: 0.010 mm {0.0004 in.)
I_JJ
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7-14
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Straightness
6. Place the cylinder block on the surface plate.
7. Clean and installthe bearigns on the No.1 and No.5journal of the cylinder block.
8. Lower the crankshaft into the block.
9. Measure runout on all main journals. Rotate the
crankshaft two complete revolutlons. The
difference between measurements on each journal
must not be more than the service limit.
Crankshaft Total Runout
Standard (New): 0.03 mm 10.0012 in.l max.
Service Limit: 0.04 mm (0.0016 in.l
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