Block and Piston Inspection

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

Standard (New): 89.983-89.996 mm (3.54263-3.54314 in)

Service Limit: 89.975 mm (3.54232 in)

Fig 1: Checking Piston Diameter
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 standard limit, replace the engine block.
Cylinder Bore Size

Standard (New): 90.000-90.015 mm (3.54330-3.54389 in)

Service Limit: 90.065 mm (3.54586 in)

Bore Taper

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

Fig 2: Checking Cylinder Bore Size
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 (0.0028 in) max.

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

Standard (New): 0.004-0.032 mm (0.00016-0.00126 in)

Service Limit: 0.07 mm (0.0028 in)

Fig 4: Checking Piston-To-Cylinder Bore Clearance
Courtesy of AMERICAN HONDA MOTOR CO., INC.