Engine Block: Diagnosis Honda Pilot II

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): 21.962-21.965 mm (0.86464-0.86476 in) Service Limit: 21.954 mm (0.86433 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 on the piston. Piston Pin-to-Piston Clearance Standard (New): -0.0050-0.0010 mm (-0.000197-0.000039 in) Service Limit: 0.004 mm (0.00016 in)
4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.005-0.014 mm (0.00020-0.00055 in) Service Limit: 0.019 mm (0.00075 in)

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1. Install a piston pin snap ring (A) only on one side.
2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.
3. Heat the piston to about 158°F (70°C).
4. Assemble the piston (A) and the connecting rod (B) with the embossed marks (C) on the same side. Install the piston pin (D). NOTE: Apply new engine oil to the piston pin.
5. Install the remaining snap ring.
6. Reassemble the other pistons the same way.

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1. Remove the pistons from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-333552-S30813783042009072100000) ).
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 ring and second ring grooves are 1.2 mm (0.05 in.) wide, and the oil ring groove is 2.8 mm (0.11 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 (0.6-0.8 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 step 4 on «BLOCK AND PISTON INSPECTION»(ref-333552-S02123346002009072100000) ). If the bore is over the service limit, the engine block must be rebored. Piston Ring End-Gap Top ring: Standard (New): 0.20-0.35 mm (0.0079-0.0138 in) Service Limit: 0.60 mm (0.0236 in) Second Ring: Standard (New): 0.40-0.55 mm (0.0157-0.0217 in) Service Limit: 0.70 mm (0.0276 in) Oil Ring: Standard (New): 0.20-0.70 mm (0.0079-0.0276 in) Service Limit: 0.80 mm (0.0315 in)
6. Install the rings as shown. The top ring (A) has a 1D mark and the second ring (B) has a 2X mark. The manufacturing marks (C) must face upward. Piston Ring Dimensions
7. After installing a new set of rings, measure the ring-to-groove clearance: Top Ring Clearance Standard (New): 0.055-0.080 mm (0.0022-0.00315 in) Service Limit: 0.15 mm (0.0059 in) Second Ring Clearance Standard (New): 0.030-0.055 mm (0.00118-0.00217 in) Service Limit: 0.13 mm (0.0051 in)
8. Rotate the rings in their grooves to make sure they do not bind.
9. Position the ring end gaps as shown below