ENGINE UNIT REPAIR

Tech Tips


  • Bore all the 4 cylinder to fit the O/S piston outside diameter.

  • Replace all the piston rings with ones to match the O/S pistons.


  1. BORE CYLINDER


    1. Prepare 4 new O/S pistons.

      O/S 0.50 piston diameter
      99.950 to 99.980 mm (3.9350 to 3.9362 in.))
    2. A01E140E03

      Using a micrometer, measure the piston diameter at right angles to the piston pin center line where the distance from the piston head is as specified.

      Standard distance
      61.27 to 61.33 mm (2.4122 to 2.4146 in.)

    3. Calculate the amount each cylinder is to be rebored as follows.

      Tech Tips


      • Size to be rebored = P + C - H

      • P = Piston diameter

      • C = Piston clearance: 0.040 to 0.060 mm (0.0016 to 0.0024 in.)

      • H = Allowance for honing: 0.02 mm (0.0008 in.) or less

    4. Bore and hone the cylinders to the calculated dimensions.

      Maximum honing
      0.02 mm (0.0008 in.)

      Note

      Excess honing will destroy the finished roundness.