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Crankshaft and Piston Removal

WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine/IMA motor/transmission assembly (see ENGINE REMOVAL ).
  2. Remove the transmission (see TRANSMISSION REMOVAL ).
  3. Remove the IMA motor housing (see DRAIN COVER REMOVAL/INSTALLATION ).
  4. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
    Fig 1: Identifying Crankshaft Position (CKP) Sensor Cover And CKP Sensor Connector
    G06428980Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the harness cover (C).
  6. Remove the oil pan (see OIL PAN REMOVAL  ).
  7. Remove the oil pump (see REMOVAL ).
  8. Remove the cylinder head (see CYLINDER HEAD REMOVAL ).
  9. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
    Fig 2: Identifying Bearing Cap Bolts Tightening Sequence
    G06428981Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Remove the bearing cap bridge.
  11. Remove the connecting rod caps/bearings. Keep all caps/bearings in order.
  12. Lift crankshaft (A) out of the engine block, being careful not to damage the journals and the CKP pulse plate (B).
    Fig 3: Identifying Crankshaft And CKP Pulse Plate
    G06428982Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Remove the CKP pulse plate.
  14. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
  15. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.
    Fig 4: Removing Hard Carbon
    G06428983Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B). Take care not to damage the cylinder with the connecting rod.
    Fig 5: Removing Piston/Connecting Rod Assembly
    G06428984Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Reinstall the bearing cap bridge and bearings on the engine block.
  18. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
  19. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in original order.
    NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.
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