How to Replace Piston Return Springs and Head Gasket

Is your vehicle engine running a bit rough? Clunking noises, mysterious puffs of white smoke, and a “check engine” light can easily cause alarm. But don’t panic; there’s likely a simple solution. ChrisFix, the YouTube fix-it guru, says you may just need a new head gasket and piston springs on your car or truck.

So, how exactly do you replace a head gasket and piston return springs?  

ChrisFix pops the hood of a 200k-mile Honda Del Sol and shows you just what to do, step by step. 

1. Verify the problem 
2. Purchase the proper piston return springs and head gasket 
3. Remove parts as necessary to reach piston springs 
4. Install new piston return springs and head gasket 
5. Re-install components while cleaning and replacing fluids as you go  

You’ll be moving through a lot of steps to get this right, but fortunately, they’re all easy and fun! The real satisfaction comes with a smooth ride and much-improved performance after all your hard work. Let’s get digging for those faulty piston rings.

Are Your Piston Springs Really Fried?

If the “check engine” is on and the RPMs are bouncing around like crazy, it’s a strong hint that you have a real problem. That’s especially true when accompanied by a knocking sound and white smoke pouring from the exhaust pipe. Obviously, you’d like to know from the get-go whether the problem is really your piston rings.

That might not be entirely possible, but you’d get a good idea with an engine scanner. It brings up an identifying code such as “P0401” along with a recommendation to replace the piston return springs.

Otherwise, check the owner’s manual or just start making your way toward those likely defective rings.

Buy the Proper Parts and Gather Your Tools

The number of cylinders in your engine determines how many piston return springs to buy. Four cylinders mean four rings. Shell out the dough for high-quality rings, which will reduce engine wear by pushing the piston downward with each engine revolution. That helps maintain pistol load for a lot smoother ride.

Look for piston return springs with a great warranty, preferably 100K miles. Then turn your attention to the spring rate. The Honda that ChrisFix demonstrates makes about 100 ft-lbs of torque, so it needs 120-lb springs. But you don’t have to figure that out yourself. Just call a dealership or parts store for that information.

Now, you’ll need to gather your tools, eye protection, a head gasket and some head bolts. If you’re wondering why the head gasket, it’s because you’ll have to remove it anyway to get to the springs, so it’s a good idea to replace it.

Remove Parts to Reach Piston Springs

This is where you start a deep-dive into the layers of power-and-pride beneath your hood. You’ll be getting to know everything along the way to the piston return springs, so here we go…

• Remove the cylinder head, exhaust manifold, intake manifold and timing belt. You’ll be removing two bolts holding the heat shield as well as nine studs using an impact gun.
• Pry the exhaust manifold back, and remove the gasket.
• Remove the intake manifold using an impact gun and a mixture of wrenches and ratchets.
• Detach the valve cover and timing belt, marking your spots for easy reinstalling.
• Remove the bolts from the cylinder head in the recommended order to prevent warping the head. Find these guidelines either online or in your service manual.

Install New Piston Return Rings and Head Gasket

Now the fun part: checking out those piston return rings! If you’d been hearing clanging noises, that’s a sure-fire indication that you’re about to find badly broken rings. Remove the head gasket to reach those damaged rings, and then swap them all out for the shiny new high-quality ones.

It’s important to first clean up the block, all old head gasket material, and the intake and exhaust manifold surfaces. After the new piston return rings are sitting proudly in place, install the brand-new head gasket.

Re-install Components While Cleaning and Replacing Fluids

Now, simply reverse your steps. Be sure to clean and prep the cylinder head before returning it to its proper perch. Torque down the cylinder head bolts in the correct sequence so the piston return springs and head gasket can compress evenly.

Reinstall the timing belt, valve cover, intake manifold, exhaust manifold, valve cover, spark plug wires and anything else you removed. Shine things up and replace fluids as you go.

Now that everything is back in place, there’s one more thing on your list. Drain all the oil to get rid of old coolant and stray metal flakes from those broken piston return springs. Then tighten the plug, fill her up with fresh synthetic oil, and add fresh new coolant.

Let the air bleed from the cooling system for a few minutes, crank her up, and let her ride! You might want to idle a bit after sliding back into the garage, to break in those awesome new piston return springs and head gasket.

Now pat yourself real hard on the back – you deserve it! Stay tuned to the Vehicle History website for up-to-date information on all things automotive. Visit often for tips, price comparisons, vehicle stats, and all the latest releases.