ENGINE UNIT (w/ DPF) REPAIR


  1. BORE CYLINDER

    Tech Tips


    • Bore all 4 cylinders for the O/S piston outside diameter.

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


    1. Keep 4 new O/S pistons.

      Piston Diameter
      O/S 0.50 O/S 0.75 O/S 1.00
      96.42 to 96.45 mm (3.7960 to 3.7972 in.) 96.67 to 96.70 mm (3.8058 to 3.8071 in.) 96.92 to 96.95 mm (3.8157 to 3.8169 in.)
    2. A01KHOCE03
      Text in Illustration
      *a Front Mark (Arrow)
      *b Size Mark
      *c Piston Pin Hole Inside Diameter Mark
      *d Distance

      Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

      Distance
      63.5 mm (2.50 in.)

    3. Calculate how much each cylinder needs to be rebored:

      Size to be rebored
      Size to be rebored = P + C - H
      P = Piston diameter
      C = Piston clearance: 0.070 to 0.090 mm (0.0028 to 0.0035 in.)
      H = Allowance for honing: 0.02 mm (0.0008 in.) or less

    4. Bore and hone the cylinders to calculated dimensions.

      Maximum honing
      0.02 mm (0.0008 in.)

      Note

      Excess honing will destroy the finished roundness.