Ford Fiesta Sleeved DV6 block

[TDR|XTC]

Hello!

If anyone has experience with adding custom sleeves to an engine please help me out!

I am planning on modifying the 1.6 DV6 16v block from a 2009 Ford Fiesta 2009 (currently at 200bhp) but wanting to push way more. An option would be to cut the cylinders and add custom sleeves. Of course not being a very popular tuned engine, there aren't ready made sleeves for it. However i did browse the web to try and find something that might fit the block. And I came across Darton Sleeves which have a kit of Honda D16 sleeves (sleeves code is Darton 400-100, 75mm bore just like the Fiesta).

Sadly i do not have CAD data model for the DV6 block and i can't do a simulation about this fitment.

I do have some specs here:

1. Of the OEM liners, a sheet from Mahle that you can find here: https://catalog.mahle-aftermarket.com/eu/product.xhtml?eid=1025462#divider

2. The manual of the Honda D16 sleeve installation from Darton that you can find here: https://dartonsleeves.com/pdf/Honda_manual.pdf

What i could deduce until now is that the current OEM liners/cylinders are 1mm longer than the length of the Darton sleeves and that the top flange of the sleeves sit on a 11cm diameter and on the DV6 engine the diameter between water jacket interior walls is 10cm.

Any thoughts would be very helpful!

Thank you.