Inspection and Service

INSPECTION





1. Measure wear and taper in directions X and Y at three levels in each cylinder as shown.

Cylinder Bore Size
B16A2 engine:
Standard (New): 81.00 - 81.02 mm (3.183 - 3.190 inch)
Service Limit: 81.07 mm (3.192 inch)
D16Y5, D16Y7, D16Y8 engines:
Standard (New): 75.00 - 75.02 mm (2.953 - 2.954 inch)
Service Limit: 75.07 mm (2.956 inch)

Oversize
B16A2 engine:
0.25: 81.25 - 81.27 mm (3.199 - 3.200 inch)
D16Y5, D16Y7, D16Y8 engines:
0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 inch)
0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 inch)

Bore Taper
Limit: (Difference between first and third measurement) 0.05 mm (0.002 inch)

- If the measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block.
- If the block is to be rebored, refer to Piston Clearance Inspection after reboring. See Piston, Engine / Testing and Inspection.

NOTE: Scored or scratched cylinder bores must be honed.

Reboring Limit:
B16A2 engine: 0.25 mm (0.01 inch)
D16Y5, D16Y7, D16Y8 engines: 0.50 mm (0.02 inch)








2. Check the top of the block for warpage. Measure along the edges and across the center as shown

Engine Block Warpage:
B16A2 engine:
Standard (New): 0.05 mm (0.002 inch) max.
Service Limit: 0.08 mm (0.003 inch)
D16Y5, D16Y7, D16Y8 engines:
Standard (New): 0.07 mm (0.003 inch) max.
Service Limit: 0.10 mm (0.004 inch)

BORE HONING








1. Measure cylinder bores. If the block is to be reused, hone the cylinders and remeasure the bores.

2. Hone cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern.

NOTE:
- Use only a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent.
- Do not use stones that are worn or broken.

3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil immediately to prevent rusting.

NOTE: Never use solvent, it will only redistribute the grit on the cylinder walls.

4. If scoring or scratches are still present in cylinder bores after honing to the service limit, rebore the cylinder block.

NOTE: Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

NOTE:
- After honing, clean the cylinder thoroughly with soapy water.
- Only a scored or scratched cylinder bore must be honed.