Block and Piston Inspection

Remove the piston from the engine block (see CRANKSHAFT AND PISTON REMOVAL ).
Check the piston for distortion or cracks.
Measure the piston diameter at a point 16.0 mm (0.63 in.) from the bottom of the skirt.
Piston Diameter

Standard (New): 88.975-88.985 mm (3.5029-3.5033 in.)

Service Limit: 88.965 mm (3.5026 in.)

Oversize Piston Diameter

0.25: 89.225-89.235 mm (3.5128-3.5132 in.)

Fig 1: Measuring Piston Diameter
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure 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, replace the block. If the block has to be rebored, refer to step 7 after reboring.
Cylinder Bore Size

Standard (New): 89.000-89.015 mm (3.5039-3.5045 in.)

Service Limit: 89.065 mm (3.5065 in.)

Oversize

0.25: 89.250-89.265 mm (3.5138-3.5144 in.)

Reboring Limit: 0.25 mm (0.01 in.)

Bore Taper

Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)

Fig 2: Identifying Cylinder Wear And Taper Measuring Direction
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Scored or scratched cylinder bores must be honed (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 (0.003 in.) max.

Service Limit: 0.10 mm (0.004 in.)

Fig 3: Checking Top Of Engine Block For Warpage
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Calculate the difference between cylinder bore diameter and piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and engine block for excessive wear.
Piston-to-Block Clearance

Standard (New): 0.015-0.040 mm (0.0006-0.0016 in.)

Service Limit: 0.08 mm (0.003 in.)

Fig 4: Identifying Difference Between Cylinder Bore Diameter And Piston Diameter
Courtesy of AMERICAN HONDA MOTOR CO., INC.