Block and Piston Inspection

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Remove the pistons from the engine block (see CRANKSHAFT AND PISTON REMOVAL ).
Check the pistons for distortion or cracks.
Measure the piston skirt diameter at a point 16 mm (0.63 in) from the bottom of the skirt.
Piston Skirt Diameter

Standard (New): 88.975-88.985 mm (3.50295-3.50334 in)

Service Limit: 88.965 mm (3.50255 in)

Oversize Piston Skirt Diameter

0.25: 89.225-89.235 mm (3.51279-3.51318 in)

Fig 1: Identifying Piston Skirt Diameter At Point 16 mm (0.63 in) From Bottom Of Skirt
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Measuring Piston Skirt Diameter At Point 16 mm (0.63 in) From Bottom Of Skirt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit or the cylinders are damaged, replace the engine block. If the engine block has to be rebored, refer to step 7 after reboring.
Cylinder Bore Size

Standard (New): 89.000-89.015 mm (3.50393-3.50452 in)

Service Limit: 89.065 mm (3.50649 in)

Oversize

0.25: 89.250-89.265 mm (3.51377-3.51436 in)

Reboring Limit: 0.25 mm (0.0098 in)

Bore Taper

Limit: (Difference between first and third measurement) 0.05 mm (0.0020 in)

Fig 3: Identifying Bore Taper Measurement
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 4: Identifying Cylinder Wear And Taper Measuring Direction
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Hone any scored or scratched cylinder bores (see CYLINDER BORE HONING ).
Check the top of the engine block for warpage. Measure along the edges and across the center as shown.
Engine Block Warpage

Standard (New): 0.07 mm (0.002 in) max.

Service Limit: 0.10 mm (0.003 in)

Fig 5: Identifying Engine Block Warpage Measuring Positions
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 6: Checking Top Of Engine Block For Warpage
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and the cylinder bore for excessive wear.
Piston-to-Cylinder Bore Clearance

Standard (New): 0.015-0.040 mm (0.001-0.001 in)

Service Limit: 0.08 mm (0.003 in)

Fig 7: Identifying Difference Between Cylinder Bore Diameter And Piston Diameter
Courtesy of AMERICAN HONDA MOTOR CO., INC.