eTiLiKo

I'll try to make the story short. I built a good number of Honda, Mitsu, Nissan etc. engines in the last few years.
The subject of this issue is a BRAND NEW H22A7 short block. NEW from honda dealer, bought at a very good price because it was in the depot for years.
I have disassembled it to check everything, clean all the OEM grease in it and lubricate. All the things concerning main bearings and cranck was OK.
I started to reassemble it, using for reference the USDM 1993 Prelude service manual. Oiled the bolt threads (I have reused the old bolts), put a good amount of redline assembly lube on bearings, and tightened at 55lb-ft in order.
Surprise, the cranck doesn't turn free! I have made some other attempt, and found that if I tighten the 5th main cap (the smallest) less than the others the cranck turns free! The good tightening torque seems to be 52ft-lb for 1st to 4th caps and 48ft-lb for the 5th main cap.
This doesn't make sense to me.
Anyone of the reputable engine builders in HT has ever seen something like this on a H22?

DDTECH

You should do a rotation of the crank after each cap is tighten down.

Go back and disassemble and start over. When you tight down each cap.. you need to make a full rotation of the crank.. when you can't move it anymore, you've found your problem.

From there you can tell if you need to change bearing clearences or what not.

eTiLiKo

I have already tried to rotate, and the problem is on the last cap, the 5th, the smallest. The bearing clearance on this cap is already on the large side, it's 0.030mm when honda spec is 0.009-0.033mm.

DDTECH

go to .033

eTiLiKo

0.003mm is...nothing, I have to do a little math to see if it's possible.
Tomorrow I'll check if the cranck is straight on the main, but it's a BRAND NEW cranck!

eTiLiKo

The cranck runout is OK, measured on the center journal with the cranck supported on outer journals, it is 0.02mm.
journal taper and out of bore is OK.

I have tried to measure main caps distortion without main bearings. It is 0.02mm with mains torqued to spec. To minimize distortion I have to torque the mains to 60Nm (44 ft-lbs).
IT IS A BRAND NEW cylinder block, how it is possible???
The only block mod is a kaizenspeed balancer shaft removal kit.

DDTECH

I'd have a machine shop go back and line hone everything and make sure everything is on point.. You're only going to be able to do so much without a machine.

casting tolerences?? I dont know.. but i wouldn't proceed any futher until something is machine measured.

eTiLiKo

Anyone else have seen main cap distortion on a fully functional H22 cylinder block?

dc4teg

I had a issue like this but it was not on the main caps, it was on the cam caps. I took it to a machine shop and end up having to get a new head. Something was outta spec with the cap closest to the timing belt. They couldnt line bore it for some reason. That kinda thing is annoying to deal with because you cant see the problem with your eyes. Please if you figure this out let us know because I have an h2b so I like to get knowledge of things like this.

eTiLiKo

I'll update for sure.
But my case is very different from your. I can see everything because I build engines from years. I have many torque wrenches, digital mic, bore gauge, dial indicators, plastigauge, etc. etc.
I have taken more measure : to have an acceptable balance between caps distortion and caps load I'll have to torque the 2nd and 5th caps, the smallest, at 60Nm (44ftlbs) and the others to 70Nm (52ftlbs).
If someone on this board have built a lot of H22 engines, maybe have encountered this problem...

PyroProblem

Just for ***** and giggles, what would happen if you swapped the crank around 180 and re-torqued the main caps?
Put the nose of the crank where the flywheel would go, and the flywheel side where the ol pump would go...
Perhaps this will help pinpoint if its the block's mains that are out, or the crankshaft...

EG1834

At which cap are the thrust bearings?

PyroProblem

I think #4

xzodiackillerx

is the cap on the right way? I know its a dumb question but it wouldn't hurt to check

eTiLiKo

Ehehehe, it's in the right way, yes. All the normal checks have been made and not show abnormalities.
The thrust bearings on the H22 is on one of the biggest caps, the #4 if I remember correct.