Complete removal and replacement of the short block assembly (engine block, crankshaft, pistons, and connecting rods) while retaining the cylinder head and timing components.

Warnings

Tools required

Parts

• Short block assembly (block, crankshaft, pistons, rods) × 1 — Use OEM specification
• Main bearing set × 1 — Use OEM specification
• Rod bearing set × 1 — Use OEM specification
• Piston ring set (if pistons reused) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Head gasket × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Oil pump O-ring and seal kit × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — 94109-14000
• Coolant hose clamps (assorted) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Head bolts (TTY) × 1 — Use OEM specification
• Engine assembly lube × 1 — Use OEM specification

Fluids

• Honda Genuine 0W-20 engine oil — 4 qt
• Honda Type 2 Coolant (Blue) — 6 qt
• Honda DW-1 ATF (if transmission removed) — 8 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Remove engine cover and upper plastic covers
4. Drain engine oil completely and remove oil filter
5. Drain coolant from radiator and engine block drain plugs
6. Remove front wheels and lower splash shields
7. Remove air intake system from air box to turbocharger inlet
8. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
9. Label and photograph all electrical connections, vacuum lines, and coolant hoses for reassembly reference
10. Support vehicle on jack stands at all four corners if transmission will be removed
11. Prepare clean workspace with engine stand for disassembly

Procedure

1. 1

   Remove cylinder head
   Disconnect all wiring harnesses, coolant hoses, fuel lines, and vacuum lines from cylinder head. Remove turbocharger assembly with manifold if still attached. Remove ignition coils and spark plugs. Remove valve cover. Set cylinder #1 to TDC compression stroke by aligning timing marks. Lock timing chain or mark chain-to-sprocket positions with paint. Remove timing chain tensioner. Remove camshaft sprockets. Remove cylinder head bolts in reverse of tightening sequence (spiral pattern from outside to inside). Carefully lift cylinder head straight up and place on padded surface with combustion chambers facing up. Cover head to prevent debris contamination.
2. 2

   Remove timing components and front covers
   Remove crankshaft pulley bolt using breaker bar or impact wrench while holding flywheel with flywheel lock tool. Remove crankshaft pulley. Remove timing chain guide and chain from crankshaft sprocket. Remove timing cover bolts in sequence and remove timing cover. Remove front crankshaft seal from timing cover. Remove oil pump from front of engine block if separate from timing cover assembly.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Cover Bolts15 Nm (11 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
3. 3

   Disconnect engine accessories and mounts
   Remove alternator, A/C compressor (leave hoses connected and secure aside), and power steering pump bracket if applicable. Disconnect all remaining electrical connectors including knock sensor, oil pressure sensor, and crankshaft position sensor. Remove engine mount brackets from engine block sides. Tag location of each mount bracket for correct reinstallation.
   Torque spec

   Mounting Bolts45 Nm (33 lb-ft)

   Sensor Bolts10 Nm (8 lb-ft)
4. 4

   Separate transmission from engine
   Support transmission securely with transmission jack. Remove starter motor. Remove flywheel/flexplate inspection cover. Remove all transmission-to-engine bolts. For manual transmission, remove clutch pressure plate and disc, noting flywheel side of disc. For automatic transmission, access torque converter bolts through starter opening and remove all bolts. Carefully pull transmission straight back away from engine, ensuring torque converter (automatic) stays with transmission. Lower transmission on jack and secure safely.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
5. 5

   Remove flywheel and rear main seal
   Lock flywheel using flywheel holder tool. Remove flywheel bolts in star pattern, working progressively looser. Remove flywheel and mark orientation to crankshaft for reinstallation. Using seal puller or screwdriver, carefully pry out rear main seal from crankshaft housing. Clean seal bore thoroughly.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
6. 6

   Remove oil pan and pickup tube
   Remove all oil pan bolts in crisscross pattern from outside to inside. Carefully break oil pan seal using plastic gasket scraper or soft mallet taps. Remove oil pan and gasket. Remove oil pickup tube mounting bolts and remove pickup tube with O-ring. Inspect pickup screen for debris.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
7. 7

   Prepare engine for removal
   Attach engine hoist to factory lifting points on engine block. Take up slack in hoist chain to support engine weight. Remove remaining engine mount bolts from block. Verify all electrical connections, hoses, and brackets are disconnected. Carefully lift engine from engine bay, tilting as necessary to clear subframe and body. Place engine on engine stand and secure with minimum four bolts into bellhousing mounting holes.
   Torque spec

   Mounting Bolts45 Nm (33 lb-ft)
8. 8

   Disassemble short block - remove pistons
   Rotate engine on stand to access cylinder bores. Check for ridge at top of cylinder bores - use ridge reamer if ridge is present to prevent ring damage during removal. Mark each connecting rod cap and rod with cylinder number and orientation (mark faces together). Remove connecting rod cap bolts and caps, keeping each cap with its rod. Push piston and rod assemblies out top of block. Place each piston assembly in labeled container or bag with its rod, cap, and bearings together for inspection.
   ⚠Rod caps and rods are matched sets and must not be mixed between cylinders. Keep each rod assembly together and properly labeled.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Remove crankshaft and main bearings
   Mark each main bearing cap with cylinder number and orientation arrow pointing toward front of engine. Remove main bearing cap bolts in sequence from outside caps working toward center. Carefully remove each main cap and store with its bolts. Lift crankshaft straight up out of block. Remove upper bearing shells from block and lower bearing shells from caps. Keep bearings organized by position for inspection. Inspect crankshaft journals for scoring, out-of-round, or damage.
   ⚠Main bearing caps must be installed in exact original positions and orientation. Arrows on caps must point toward front of engine.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Prepare and inspect new short block
    Thoroughly clean new short block with solvent and compressed air, paying special attention to oil passages. Verify all core plugs are properly installed. Check cylinder bores for any shipping damage or debris. Measure cylinder bore diameter and out-of-round at multiple points. Inspect crankshaft journals with micrometer for proper size and finish. Verify deck surface is flat and clean. Install new core plugs if block came without them. Blow out all oil passages with compressed air.
    ⚠New short blocks often have protective coating in cylinders and on bearings. Remove per manufacturer instructions before assembly.
11. 11

    Install crankshaft and verify bearing clearances
    Liberally coat all main bearing surfaces in block with assembly lube. Install upper main bearing shells into block, ensuring bearing tabs engage slots. Lay strips of Plastigage across each crankshaft main journal. Carefully lower crankshaft into block. Install lower bearing shells into main caps with assembly lube. Install main caps in correct positions with arrows toward front. Install new main bearing cap bolts finger tight. Torque main cap bolts to 75 Nm (55 lb-ft) in sequence from center outward, then rotate additional angle per service manual specifications (typically 90 degrees). Remove caps carefully and measure Plastigage width to verify bearing clearance is within specification (typically 0.025-0.050mm). If clearance is incorrect, determine cause before proceeding.
    ⚠️Do NOT rotate crankshaft with Plastigage installed. This will give false readings and may damage bearings.
    ⚠After torquing TTY main bearing bolts for clearance check, these bolts must be discarded and new bolts used for final assembly.
    Torque spec

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

    Final crankshaft installation
    Remove main caps again and thoroughly clean all Plastigage residue from bearings and journals using clean solvent. Reapply assembly lube to all bearing surfaces. Reinstall crankshaft and main caps with new main bearing cap bolts. Torque main cap bolts in proper sequence to 75 Nm (55 lb-ft), then rotate additional specified angle. Verify crankshaft rotates smoothly by hand with no binding. Check crankshaft endplay with dial indicator (specification typically 0.06-0.24mm). Install rear main seal using seal driver, ensuring seal is flush and square to crankshaft.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Prepare and install pistons
    If reusing pistons from old engine, clean pistons thoroughly and remove old rings. Install new piston rings on each piston per ring package instructions, ensuring ring gaps are properly staggered around piston (typically 120 degrees apart). Coat piston rings, pistons, and cylinder walls liberally with assembly lube. Install rod bearing shells in connecting rods with assembly lube. Lay Plastigage on each rod journal of crankshaft. Using piston ring compressor, compress rings on piston #1 and carefully tap piston into cylinder #1, ensuring orientation mark on piston crown faces front of engine. Guide connecting rod onto journal #1. Install rod bearing cap with assembly lube in correct orientation. Install new rod bolts finger tight, then torque to 45 Nm (33 lb-ft) plus additional angle per specification. Repeat for remaining cylinders. Remove caps and verify rod bearing clearance with Plastigage before final assembly.
    ⚠Piston orientation is critical. Arrow or mark on piston crown must face front of engine. Installing backwards will cause interference with valves.
    ⚠Do not force pistons into cylinders. If piston will not enter smoothly, rings are not properly compressed or are caught on ridge.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Final piston and rod installation
    Remove all rod caps again and clean all Plastigage residue thoroughly. Verify all rod bearing clearances are within specification. Reinstall all rod caps with new rod bolts and assembly lube. Torque each rod bolt to 45 Nm (33 lb-ft) in proper sequence, then rotate additional specified angle (typically 60-90 degrees). After all rods are torqued, rotate crankshaft by hand through two complete revolutions, checking for smooth rotation and any binding. Verify each piston reaches top and bottom of stroke without interference.
    Torque spec

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

    Install oil pump and pickup tube
    Install new O-ring on oil pickup tube with light oil coating. Install pickup tube into block and torque bolts to 12 Nm (9 lb-ft). Apply thin bead of Honda Bond HT RTV to oil pump mating surface if required. Install oil pump to front of block or into timing cover per design. Torque oil pump bolts to 12 Nm (9 lb-ft). Pack oil pump with petroleum jelly to prime pump before installation. Install new front crankshaft seal into timing cover using seal driver, ensuring seal is flush and square.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)
16. 16

    Install oil pan
    Clean oil pan and block mating surfaces thoroughly with brake cleaner. Install new oil pan gasket or apply thin continuous bead of Honda Bond HT RTV per service manual specification. Install oil pan and hand-start all bolts. Torque oil pan bolts in crisscross pattern from center outward to 12 Nm (9 lb-ft). Allow RTV to cure for 30 minutes minimum before adding oil. Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft).
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
17. 17

    Install timing components and covers
    Install timing cover with new gasket or RTV per specification. Torque 8mm timing cover bolts to 25 Nm (18 lb-ft) in proper sequence. Install crankshaft sprocket on crankshaft nose, ensuring keyway is aligned. Install timing chain onto crankshaft sprocket. Install chain guide. Rotate crankshaft to align timing marks. Apply thread locker to crankshaft pulley bolt threads. Install crankshaft pulley and torque bolt to 180 Nm (133 lb-ft), using holding tool on flywheel to prevent rotation.
    ℹ️Timing chain installation will be completed after cylinder head installation. Chain cannot be timed without camshafts in place.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
18. 18

    Install flywheel and transmission
    Clean flywheel and crankshaft flange surfaces. Align flywheel to crankshaft in original orientation. Install new flywheel bolts and torque in star pattern to 95 Nm (70 lb-ft). For manual transmission, install new clutch disc (marked side toward flywheel) and pressure plate using alignment tool. For automatic transmission, align flexplate and torque converter. Position transmission on jack and align with engine. Install all transmission-to-engine bolts and torque to 55 Nm (41 lb-ft) in star pattern. Install torque converter bolts if automatic. Install starter motor.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
19. 19

    Install cylinder head
    Clean block deck surface thoroughly and verify surface is perfectly clean and dry. Install new head gasket on block with orientation marks up and toward front. Verify head gasket is correct part number for turbo 1.5L engine. Carefully lower cylinder head onto block, aligning dowel pins. Install new head bolts finger tight. Torque head bolts in proper spiral sequence per service manual (typically from center outward) following multi-stage torque and angle specifications. Install camshaft sprockets and align timing marks with chain. Install timing chain tensioner. Verify all timing marks are correctly aligned before proceeding.
    ⚠️Head bolt torque sequence and specifications are critical. Incorrect torque or sequence will cause head gasket failure. Follow exact service manual procedure including multiple stages and angles.
    Torque spec

    Gasket Bolts19 Nm (14 lb-ft)
20. 20

    Reinstall engine and accessories
    Using engine hoist, carefully lift engine assembly and guide into engine bay. Align engine mounts and install mount bolts, torquing to specified values (26 Nm for smaller mounts, 45 Nm for primary mounts as applicable). Reconnect all electrical connectors including sensors, alternator, and starter. Install A/C compressor and alternator with drive belt. Reconnect all coolant hoses with new clamps. Reconnect fuel lines and vacuum lines per reference photos. Install turbocharger assembly if removed separately. Install air intake system. Install valve cover with new gasket. Install ignition coils and new spark plugs. Reconnect all wiring harnesses.
    Torque spec

    Mounting Bolts45 Nm (33 lb-ft)
21. 21

    Fill fluids and initial start
    Install new oil filter hand-tight plus 3/4 turn. Fill engine with 4 quarts Honda Genuine 0W-20 oil. Fill cooling system with 6 quarts Honda Type 2 Blue coolant mixed per specification. Refill transmission with Honda DW-1 ATF if drained. Double-check all connections, bolts, and hoses. Reconnect battery. Remove spark plugs and disable fuel injection by disconnecting injector harness. Crank engine for 10 seconds to build oil pressure - verify oil pressure light goes out. Reinstall spark plugs and reconnect injectors. Start engine and verify oil pressure immediately. Check for any leaks while engine warms up. Allow engine to reach operating temperature while monitoring for leaks and unusual noises.
    ⚠️If oil pressure light does not go out within 2 seconds of cranking or starting, shut down immediately and investigate. Running engine without oil pressure will cause catastrophic damage.

Reassembly

1. Reinstall all splash shields and undercarriage covers
2. Install front wheels and torque lug nuts to specification
3. Lower vehicle to ground
4. Bleed cooling system completely per Honda procedure to remove air pockets
5. Check and adjust coolant level after bleeding
6. Reset ECU by disconnecting battery for 30 seconds if necessary for idle relearn
7. Install engine cover and all trim pieces

Verification

• Verify no coolant, oil, or fuel leaks after engine reaches full operating temperature
• Check engine oil level on dipstick and adjust as necessary - do not overfill
• Verify coolant level in reservoir is at FULL mark when engine is cold
• Monitor oil pressure gauge or light during test drive - pressure should be normal at all speeds
• Test drive vehicle and verify smooth operation through full RPM range
• Listen for any unusual noises including knocking, ticking, or grinding that could indicate assembly issues
• Scan for any diagnostic trouble codes and verify none are present
• Recheck all fluid levels after test drive and top off as necessary
• Perform leak inspection after test drive with engine at operating temperature
• Change engine oil and filter after 500 miles of break-in driving
• Monitor oil consumption for first 1000 miles - some consumption during break-in is normal but should not be excessive

More procedures for this vehicle