kartman01 dropped off his Pilot Engine for a CSI, he is doing a Pilot resto what better time to go through the Engine to ensure its up to snuff.

After removing the head I found light scuffing on the cylinder wall and trails of light blow by can be seen.

Exhaust is messy, this is a 1990 cylinder and full of the typical casting flaws, the 89 castings were so much nicer and higher quality.

Note the end of the exhaust flange is bent.

The metal ring on the exhaust was missing.

Red arrows show some of the casting flaws.

After removing the cylinder I discovered who ever rebuilt this last time never scraped off all the old gasket material the current gasket is brown, all the green you see is the gasket that was before this rebuild, some left on the gasket surface itself, the lose gasket material they didnt even bother to clean up before assembling the Engine, you look at the brown gasket and you can see green gasket material stuck to it, wonder how much fell into the bottom end then was never removed before assembling then had to be washed out by running the Engine.

They must have lost one of the OEM cylinder nuts then replaced it with a after market nut, its a locking nut, how do you accurately torque a lock nut?

See the difference?

A new nut was ordered.

As found picture of the head, can see the Engine suffered some kind of internal damage at one time or another see where metal was bouncing off the piston hitting the head pitting it all up?

Cleaned up you can see the pits better.

Put the head in the lathe and removed the damage.

Turned out pretty good their is still a few small deep wounds that I didnt chase no use taking life out of the head by chasing them, head was lapped to ensure its flat.

Piston looked pretty normal just well worn, as found piston to cylinder clearance was .007

Seal behind the recoil was leaking.

Nothing abnormal found with the water pump impeller, still need to inspect further for seal leak.

Inside the stator side of the case everything nice and clean nothing abnormal found.

No signs of coolant in the balancer case oil, water pump not leaking.

Crank cases split green gaskets means someone has been inside here before.

More pics later.

Ok back to the water pump, I had some running to do today so I put the cover back on the water pump filled up the pump cavity with water and did my running a few hours later came back and it had leaked some water out the weep hole in the bottom of the cases, time for a water pump rebuild, removed the cover again then tried to remove the nut that holds the impeller on the shaft, all it did was spin and never came off, threads were stripped, tried to grab the nut with a small vicegrips and unscrew while pulling on the nut, nothing, all that was left to do was take a grinder and grind the head off to see what was going on, just as I suspected the nuts turning bot not going any place, stripped, SO next I put the cases in my drill press so I could push on the shaft and turn the nut with a wrench, that didnt work.

All that was left to do was grind both sides of the nut down to the shaft and split the nut to get it off, what a PITA

Now its apart I can see not only was the nut stripped their was parts missing, also the water pump seal had what looked and felt like grease on it, you don't GREASE these seals, probably why it leaked..

The copper washer (part 7) was missing the two dowel pins (part 9) that go on the cover were missing, and the washer (part 8) was missing.

Needless to say I need the following items added to the parts list.

19241-HE0-000 Shaft, Water Pump
19217-PA5-003 Seal, Mechanical
90441-706-000 Washer, Sealing
90201-413-000 Nut, Cap
Need TWO 94301-08140 Pin A, Dowel
19215-KA3-710 Impeller, Water Pump
90454-KA4-000 Washer
91001-KA4-003 Bearing, Radial Ball
91201-148-003 Oil Seal



Reference the above image before and during assembly to ensure you have all the parts, a critical washer was missing from this water pump assembly.

Hoser, thanks for the photos... sorry that I handed you such a challenge

I will add the water pump parts to the list for Service Honda...

Thanks!

I ordered a mechanical seal a couple weeks ago and it was on back order. It showed up just a few days after the stock stuff did. Someone else on here ordered one and it was put on back order and it also showed up in only a few days. I beleive this is one of those parts honda does not stock - but they have a supplier who ships to them pretty quick. Honda puts it in a plastic bag and a Honda sticker and sells it for a big profit. I wish I knew who that was so we could buy direct from them. 40 some bucks is to much for that seal - but we don't have much choice. Hey at least it not discontinued!!!! at leaset when service honda calls you to tell you its on bo you won't be to worried.

You think they striped the threads on the nut tring to tightenit up with out the washers and the nut crown bottomed.
Nice head work and CSI.

Any updates?

Parts here, when rebuilding the water pump everything needs to be clean so clean up the cases well, remove all the old water pump seals and the bearing shaft etc inspect everything, hopefully yours will come apart better than this one has, this is the first to give me a problem.

Press in the new water pump seal, don't TOUCH the seal surface with anything, hands, clean glove, rags, no need to touch it so don't.

I used a socket as a "seal driver" to install it just taps right in I sat down in a chair and put the case on my lap and tapped it in.

NO SEALANT IS REQUIRED on the seal it comes with a coating from the factory that does all the sealing.

The seal surface I am talking about is the surface with the red arrows.

Next install the oil seal this seal keeps the balancer oil in the balancer oil case, the last seal I installed is for keeping the coolant in the cooling system.

This seal is treated like any other oil seal you grease it before installing, it installs in the case with the little spring facing inside the balancer case or facing the bearing you install next.

I used a old Pilot crank pin as the "seal driver" works perfectly, I like it when I can recycle old parts that usually end up in the trash into a tool