2004 Honda S2000 L4-2.2LFACTORY OEM SERVICE PROCEDURE

Engine Block

Block Warpage of deck Standard or new 0.07 mm
Service limit 0.10 mm
Bore diameter A or I Standard or new 87.010 - 87.020 mm
Service limit 87.070 mm
B or II Standard or new 87.000 - 87.010 mm
Service limit 87.070 mm
Bore taper Service limit 0.05 mm
Reboring limit Service limit 0.25 mm
Piston Skirt No letter Standard or new 86.993 - 87.006 mm
Service limit 86.980 mm
Letter B Standard or new 86.983 - 83.996 mm
Service limit 86.970 mm
Clearance in cylinder Standard or new 0.004 - 0.027 mm
Service limit 0.04 mm
Ring groove width Top Standard or new 1.235 - 1.265 mm
Service limit 1.285 mm
Second Standard or new 1.230 - 1.245 mm
Service limit 1.265 mm
Oil Standard or new 2.005 - 2.025 mm
Service limit 2.05 mm
Piston rings Ring-to-grove clearance Top Standard or new 0.045 - 0.090 mm
Service limit 0.135 mm
Second Standard or new 0.040 - 0.070 mm
Service limit 0.13 mm
Ring end gap Top Standard or new 0.25 - 0.35 mm
Service limit 0.60 mm
Second Standard or new 0.60 - 0.75 mm
Service limit 0.90 mm
Oil Standard or new 0.20 - 0.70 mm
Service limit 0.80 mm
Piston pin O.D. Standard or new 22.961 - 22.965 mm
Service limit 22.953 mm
Pin-to-piston clearance Standard or new -0.003 - +0.0060 mm
Service limit 0.010 mm
Connecting rod Pin-to-rod clearance Standard or new 0.018 - 0.035 mm
Service limit 0.04 mm
Small-end bore diameter Standard or new 22.961 - 22.965 mm
Large-end bore diameter Nominal Standard or new 51.0 mm
End play installed on crankshaft Standard or new 0.15 - 0.30 mm
Service limit 0.40 mm
Crankshaft Main journal diameter Standard or new 54.976 - 55.000 mm
Rod journal diameter Standard or new 47.976 - 48.000 mm
Rod/main journal taper Standard or new 0.005 mm Maximum
Service limit 0.006 mm
Rod/main journal out-of-round Standard or new 0.004 mm Maximum
Service limit 0.006 mm
End play Standard or new 0.10 - 0.35 mm
Service limit 0.45 mm
Runout Standard or new 0.03 mm Maximum
Service limit 0.04 mm
Crankshaft bearings Main bearing-to-journal oil clearance Standard or new 0.017 - 0.041 mm
Service limit 0.050 mm
Rod bearing clearance Standard or new 0.030 - 0.054 mm
Service limit 0.060 mm
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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