CYLINDER BLOCK 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. Prepare 4 new O/S pistons.

      Standard Piston Diameter
      Item Specified Condition
      O/S 0.50 96.42 to 96.45 mm (3.796 to 3.797 in.)
      O/S 0.75 96.67 to 96.70 mm (3.806 to 3.807 in.)
      O/S 1.00 96.92 to 96.95 mm (3.816 to 3.817 in.)
    2. A01DRPXE01
      Text in Illustration
      *1 Size Mark
      *2 Piston Pin Hole Inside Diameter Mark
      *3 Front Mark (Arrow)
      *4 Distance

      Using a micrometer, measure the piston diameter according to the following conditions: 1) measure at a right angle to the piston center line, and 2) measure at the indicated distance from the piston head.

      Standard Distance
      Item Specified Condition
      w/ DPF 63.5 mm (2.50 in.)
      w/o DPF 65.00 to 65.006 mm (2.5590 to 2.5593 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: 0.07 to 0.09 mm (0.00276 to 0.00354 in.)
      H = Allowance for honing: 0.02 mm (0.000787 in.) or less

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

      Maximum honing
      0.02 mm (0.000787 in.)

      Note

      Excess honing will destroy the finished roundness.