Pistons - All

Complete removal and replacement of all pistons and connecting rods, requiring engine removal, disassembly, crankshaft removal, and precision reassembly with torque-to-yield fasteners.

Warnings

Tools required

Parts

• Piston set (4 pistons with pins and clips) × 1 — Use OEM specification
• Piston ring set (compression and oil rings) × 1 — Use OEM specification
• Connecting rod bearing set × 1 — Use OEM specification
• Main bearing set (crankshaft bearings) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Valve cover gasket and grommets × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — 94109-14000
• RTV silicone gasket maker × 1 — Honda 08718-0004
• Engine assembly lube × 1 — Use OEM specification
• Engine coolant (Honda Type 2 Blue) × 2 — Use OEM specification

Fluids

• Honda Genuine 0W-20 Engine Oil — 4 qt
• Honda Type 2 Coolant (Blue) — 6 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive cable
3. Remove engine cover and drain engine oil completely
4. Drain cooling system from radiator and engine block drain plugs
5. Recover air conditioning refrigerant using certified AC recovery equipment
6. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
7. Remove hood and front bumper cover for engine removal access
8. Label and photograph all vacuum lines, electrical connectors, and hose routing
9. Place fender covers to protect vehicle paint during engine removal
10. Ensure engine hoist has minimum 1000 lb capacity and engine stand is rated for this engine weight

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors, fuel lines, coolant hoses, vacuum lines, throttle body connections, exhaust manifold, and transmission connections. Remove engine mount bolts and carefully lift engine from engine bay using hoist. Separate engine from transmission if not already done. Mount engine securely on engine stand.
2. 2

   Remove external components
   Remove alternator, AC compressor, power steering pump bracket, fuel rail and injectors, intake manifold, exhaust manifold, turbocharger assembly, throttle body, spark plugs, ignition coils, and all accessory brackets. Label and store all hardware separately.
3. 3

   Remove valve cover and timing components
   Remove valve cover and gasket. Set engine to TDC on cylinder #1 by aligning timing marks. Remove timing chain cover, timing chain tensioner, timing chain guides, and timing chain. Remove camshafts and valve lifters, keeping them in order for inspection or reinstallation.
   ⚠Mark timing chain orientation and camshaft position before removal. Incorrect timing will cause engine damage.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
4. 4

   Remove cylinder head
   Remove cylinder head bolts in reverse of tightening sequence (start from outside, work inward). Carefully lift cylinder head straight up to avoid damaging block surface. Remove and discard cylinder head gasket. Inspect head surface for warpage or damage.
   ℹ️Cylinder head bolts are TTY and must be replaced with new bolts during reassembly.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Remove oil pan and oil pump
   Remove oil pan bolts and carefully separate oil pan from block. Remove oil pump pickup tube mounting bolt and remove pickup tube. Remove oil pump assembly and crankshaft front seal. Clean all gasket surfaces thoroughly.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
6. 6

   Inspect and remove cylinder ridge
   Rotate crankshaft to position pistons at bottom dead center. Inspect top of cylinder bores for ridge wear. If ridge is present, use cylinder ridge reamer to remove ridge before piston removal. This prevents piston ring damage during removal.
   ⚠Failure to remove cylinder ridge can break piston rings during removal, potentially damaging pistons.
7. 7

   Mark and remove connecting rods and main caps
   Mark each connecting rod and cap with cylinder number using permanent marker or stamping tool. Mark main bearing caps with position and orientation. Remove main bearing cap bolts in sequence from outer caps inward. Remove connecting rod bolts and caps, keeping caps matched to their rods.
   ⚠️All main cap bolts and connecting rod bolts are TTY and MUST be replaced. Do not reuse.
   ℹ️Rod caps and main caps are machined as matched pairs and cannot be interchanged.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)

   Connecting Rod Bolts45 Nm (33 lb-ft)
8. 8

   Remove crankshaft and pistons
   Carefully lift crankshaft from block and place on clean surface. Push pistons with connecting rods up and out through top of cylinder bores. Keep all bearings with their respective journals for inspection. Place pistons in order (cylinder 1-4) on clean work surface.
9. 9

   Disassemble pistons and inspect components
   Remove piston rings using ring installer tool, expanding rings carefully to avoid breaking. Remove piston pin circlips and press out piston pins, separating pistons from connecting rods. Inspect all components for wear, scoring, or damage. Measure cylinder bore diameter, taper, and out-of-round using dial bore gauge at multiple points. Check crankshaft journals for wear and measure with micrometer.
   ℹ️Cylinder bore must be within 0.01mm tolerance. If bores are out of spec, machining or cylinder sleeving is required.
10. 10

    Clean and prepare engine block
    Thoroughly clean block deck surface, cylinder bores, main bearing saddles, and all bolt holes using appropriate cleaners. Use thread chaser to clean all threaded holes. Inspect block for cracks using dye penetrant or magnetic particle inspection. Blow out all oil passages with compressed air. Wipe cylinder bores with clean lint-free cloth dampened with engine oil.
11. 11

    Install main bearings and crankshaft
    Install new main bearings into block saddles and main caps, ensuring bearing tabs engage notches correctly. Apply thin film of engine assembly lube to bearing surfaces. Carefully lower crankshaft into block. Install upper main bearings in caps with assembly lube. Install main bearing caps in correct positions and orientation. Install new TTY main cap bolts and torque to specification in sequence from center outward, then apply additional angle rotation as specified. Check crankshaft endplay and rotation (should rotate freely).
    ⚠️Use new TTY main bearing cap bolts. Torque in proper sequence: initial torque 75 Nm, then additional angle per Honda service manual specification.
    ⚠Verify bearing clearance using Plastigage before final assembly. Clearance should be 0.025-0.050mm.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Assemble pistons to connecting rods
    Install new pistons onto connecting rods using piston pin installation tool or press. Ensure piston orientation mark faces forward (timing chain side) and connecting rod orientation mark faces correct direction per cylinder. Install new piston pin circlips, ensuring they are fully seated in grooves. Install piston rings using ring installer tool: install oil control ring first (expander and rails), then lower compression ring, then top compression ring. Verify ring end gaps are positioned 120 degrees apart and not aligned with piston pin.
    ⚠Piston ring orientation is critical. Top ring typically has marking that must face upward. Installing rings upside-down causes oil consumption.
13. 13

    Install pistons into cylinders
    Coat piston rings and cylinder bores with clean engine oil. Rotate crankshaft to position connecting rod journal at bottom dead center for each cylinder. Install ring compressor around piston, tightening carefully to compress all rings flush with piston. Insert piston assembly into correct cylinder bore from top, ensuring piston orientation mark faces timing chain side. Use plastic hammer handle to gently tap piston crown while guiding connecting rod onto crankshaft journal. Install rod bearing halves into connecting rod and cap with assembly lube. Install rod cap in correct orientation and install new TTY connecting rod bolts.
    ⚠Do not force piston into bore. If resistance is felt, rings may not be fully compressed. Remove and check ring compressor.
14. 14

    Torque connecting rod bolts
    Torque all connecting rod bolts to initial specification of 45 Nm in sequence (cylinders 1-4), then apply additional angle rotation as specified in Honda service manual for TTY bolts. Verify each rod has proper side clearance on crankshaft journal and rotates freely. Double-check all rod caps are correctly oriented and matched to their original rods.
    ⚠️Connecting rod bolts are TTY. Torque to 45 Nm plus additional angle per specification. Never reuse old rod bolts.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
15. 15

    Install oil pump and oil pan
    Install new crankshaft front seal. Install oil pump assembly with new gasket and torque mounting bolts to specification. Install oil pump pickup tube with new O-ring and torque to 12 Nm. Apply thin bead of RTV silicone to oil pan mating surface where specified in service manual. Install new oil pan gasket and install oil pan. Torque oil pan bolts to 12 Nm in sequence from center outward.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Gasket Bolts19 Nm (14 lb-ft)
16. 16

    Install cylinder head
    Place new cylinder head gasket on block, ensuring all alignment dowels are properly engaged. Carefully lower cylinder head onto block, aligning with dowels. Install new TTY cylinder head bolts and torque in proper sequence (start from center, spiral outward) to initial torque of 65 Nm, then apply additional angle rotation per Honda specification. Install camshafts in correct positions with timing marks aligned.
    ⚠️Cylinder head bolts are TTY. Follow exact torque sequence and angle rotation specified in service manual. Incorrect sequence can warp cylinder head.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
17. 17

    Install timing components and valve cover
    Install timing chain with alignment marks correctly positioned on camshaft and crankshaft sprockets. Install chain guides and tensioner. Install timing chain cover with new gasket, torquing cover bolts to 15 Nm. Rotate engine two complete revolutions by hand and verify timing marks realign correctly. Install new valve cover gasket and grommets. Install valve cover and torque bolts to specification.
    ⚠️Verify timing marks alignment after installation. Incorrect timing will cause valve-to-piston contact and severe engine damage.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)
18. 18

    Reinstall external components and engine
    Reinstall all external components in reverse order of removal: turbocharger, exhaust manifold, intake manifold, fuel rail, throttle body, ignition coils, spark plugs, and all accessory brackets and components. Mate engine to transmission if separated. Install engine into vehicle using hoist, connect all engine mounts and torque mounting bolts to specification. Reconnect all electrical connectors, hoses, fuel lines, and vacuum lines per photos and labels from disassembly.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
19. 19

    Fill fluids and perform initial startup
    Install new oil filter and fill engine with 4 quarts of Honda Genuine 0W-20 engine oil. Install oil drain plug with new crush washer and torque to 35 Nm. Fill cooling system with Honda Type 2 coolant (6 quarts total). Reconnect battery cables (positive first, then negative). Prime fuel system by cycling ignition on/off three times without cranking. Perform initial startup and monitor for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature while monitoring coolant level and oil pressure.
    ⚠During initial startup, monitor oil pressure immediately. If oil pressure does not build within 5 seconds, shut down engine and investigate.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. All torque-to-yield fasteners (cylinder head bolts, main bearing cap bolts, connecting rod bolts) must be replaced with new parts
2. Follow exact torque sequences specified for main caps, connecting rods, cylinder head, and oil pan
3. Verify timing chain alignment marks are correct before final timing cover installation
4. Bleed cooling system completely to remove air pockets after refilling
5. Recharge air conditioning system using certified equipment after engine installation

Verification

• Engine should start immediately and run smoothly without unusual noises, knocking, or rattling
• Oil pressure should read normal (typically 30-80 psi at operating temperature depending on RPM)
• No oil, coolant, or fuel leaks visible from any component
• Engine should idle smoothly and accelerate without hesitation or misfires
• Coolant temperature should reach and maintain normal operating range (195-220°F)
• Perform road test to verify proper power delivery and no abnormal vibrations
• Recheck oil level after initial run and top off if necessary
• Monitor for first 100 miles for any leaks or unusual operation
• Change engine oil and filter after 500 miles of break-in period

More procedures for this vehicle