Engine Block: Diagnosis Honda Fit GE

Inspection

Note. Inspect the piston, the piston pin, and the connecting rod when they are at room temperature.

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1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 17.996-18.000 mm (0.7085-0.7087 in.)
2. Zero the dial indicator to the piston pin diameter.
3. Check the difference between the piston pin diameter and the piston pin hole diameter in the piston. Piston Pin-to-Piston Clearance Standard (New): 0.010-0.017 mm (0.0004-0.0007 in.)
4. Check the difference between the piston pin diameter and connecting rod small end diameter. Piston Pin-to-Connecting Rod Interference Standard (New): 0.019-0.036 mm (0.0007-0.0014 in.)

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1. Assemble the piston and connecting rod with the arrow (A) and the embossed mark (B) on the same side.
2. Insert the pilot collar (A) into the piston and the connecting rod.
3. With the arrow on top of the piston and the embossed mark on the connecting rod facing up, place the piston/connecting rod assembly (B) on the piston base head (C). Be sure you position the recessed flat area of the piston against the area of the piston base head (D) as shown.
4. Press the piston pin (E) in with the adjustable piston pin driver head and insert adjust (F) and a hydraulic press.

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1. Remove the piston from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-320456-S36456649982009071400000) ).
2. Using a ring expander (A), remove the old piston rings (B).
3. Clean all the ring grooves thoroughly with a squared-off broken ring, or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top and second ring grooves are 1.0 mm (0.039 in) wide, and the oil ring groove is 2.0 mm (0.079 in) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
4. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.59-0.79 in) from the bottom.
5. Measure the piston ring end-gap (B) with a feeler gauge: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits (see «BLOCK AND PISTON INSPECTION»(ref-320456-S12853343042009071400000) ). If the bore is over the service limit, the engine block must be rebored. Piston Ring End-Gap Top Ring: Standard (New): 0.15-0.30 mm (0.006-0.012 in.) Service Limit: 0.60 mm (0.024 in.) Second Ring (RIKEN): Standard (New): 0.30-0.42 mm (0.012-0.017 in.) Service Limit: 0.65 mm (0.026 in.) Second Ring (NIPPON PISTON RING): Standard (New): 0.35-0.50 mm (0.014-0.020 in.) Service Limit: 0.65 mm (0.026 in.) Oil Ring: Standard (New): 0.20-0.70 mm (0.008-0.028 in.) Service Limit: 0.80 mm (0.031 in.)
6. Install the rings as shown. The top ring (A) has a R or 1N mark, and the second ring (B) has a 2R or 2N mark. The manufacturing marks (C) must be facing upward.
7. Rotate the rings in their grooves to make sure they do not bind.
8. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring-to-groove Clearance RIKEN: Standard (New): 0.065-0.090 mm (0.0026-0.0035 in.) Service Limit: 0.15 mm (0.006 in.) NIPPON PISTON RING: Standard (New): 0.061-0.090 mm (0.0024-0.0035 in.) Service Limit: 0.15 mm (0.006 in.) Second Ring-to-groove Clearance Standard (New): 0.030-0.055 mm (0.0012-0.0022 in.) Service Limit: 0.12 mm (0.005 in.)
9. Rotate the rings in their grooves to make sure they do not bind.
10. Position the ring end gaps as shown

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1. Set the crankshaft to bottom dead center (BDC) for each cylinder as its piston is installed.
2. Remove the connecting rod caps, and check that the connecting rod bearing is securely in place.
3. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.
4. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine block.
5. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
7. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-320456-S07442249072009071400000) ).
8. Inspect the connecting rod bolts (see «CONNECTING ROD BOLT INSPECTION»(ref-320456-S22737657212009071400000) ).
9. Apply new engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft).
10. Tighten the connecting rod bolts an additional 90°. NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 8 of the procedure. Do not loosen it back to the specified angle.

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1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
2. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach the ring compressor to the piston/connecting rod assembly.
3. Position the piston/connecting rod assembly with the arrow (A) facing the cam chain side of the engine block.
4. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
5. Position all pistons at top dead center (TDC).

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1. Measure the diameter of each connecting rod bolt at point A and point B with a micrometer.
2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.05 mm (0-0.002 in.)
3. If the difference in diameter is out of specification, replace the connecting rod bolt.