For this segment I will be focusing on the block and it's sleeving. The cylinders were in relatively good shape, but I have been planning on more manifold pressure and to ensure no further engine damage I will sleeve the block.
Our good friends at La Sleeves have supplied us with a set of tall flange sleeves for the d16 blocks. They are one of the best performance upgrades for any Honda block, due to their focus on cost and efficiency they don't usually consider higher cylinder pressures beyond natural aspiration. I have seen stock B and D series blocks being turbocharged up to 20 psi, but I figured since the engine is out and it's not much more to install I would be safe and do a sleeve set.
With the block mounted on our mill I began by locating the cylinders and comparing to factory locations. And, as with most Honda engines they were dead on.
Now it's time to begin cutting by boring all of the original sleeve out to accommodate the new sleeves. As the cutting progressed you can see the ribbing on the original sleeves that help to retain them. If you look in the picture of the cylinder with the ribbing exposed you can get an idea of what "core shift" is. In the cylinder to the right the ribbing narrows slightly indicating that the cylinder liners were not exactly on center. Either a movement in the casting dies or the sleeves were not even all of the way around. Even with the core shifting these cylinders had a significant amount of iron all of the way around.
After the hole is bored through completely, it now needs the step on which the flange will rest. To accomodate the flange the entire top of the cylinders will have to be cut out and the block will be wide open. Next step before slamming in the sleeves, the remaining deck will need to be surfaced, because the outer deck will be lower than the sleeves. After the sleeves are installed they will get surfaced to .001" protrusion to allow for settling. The sleeves have been chilled and the block heated, so in go the sleeves with loctite. And finally the block sits with clamps on the sleeves for at least 24 hours. If you have any sleeving or engine questions you can contact us at www.ntxmachine.com.
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