Piston, Pin, and Connecting Rod Replacement: Disassembly

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.

Assemble the piston base (A), piston base spring (B), pilot pin (C), and piston base head (D) as shown.

Fig 1: Identifying Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Temporarily install the pilot collar over the pilot pin (A), and adjust the piston base head inserts as shown, then tighten the screws (B). Remove the pilot collar.

Fig 2: Installing Pilot Collar Over Pilot Pin And Adjust Piston Base Head
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Assemble and adjust the length of the piston pin driver head and shaft to 57 mm (2.2 in).

Fig 3: Assembling And Adjust Length Of Piston Pin Driver Head And Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
With the arrow on top of the piston pointing up, place the piston assembly (A) on the piston base (B).
Be sure you position the recessed fiat area of the piston against the piston base head inserts (C) as shown.

Fig 4: Pressing Pin Out With Piston Pin Driver And Pilot Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press the pin (D) out with the piston pin driver (E), the pilot collar (F), and a hydraulic press.