CYLINDER BLOCK REPAIR

BORE CYLINDER

1. Prepare 4 new O/S pistons.

2. 

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

   Standard piston diameter (O/S 0.50)
   95.441 to 95.471 mm (3.758 to 3.759 in.)

   Distance
   13.8 mm (0.543 in.)

   Table 1. Text in Illustration

   *1

   Distance

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

   Tip:
   

   • Size to be rebored = P + C - H

     P = Piston diameter

     C = Piston oil clearance: 0.013 to 0.036 mm (0.000512 to 0.00142 in.)

     H = Allowance for honing: 0.02 mm (0.000787 in.) or less

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

   Note:

   Excess honing will destroy the finished roundness.

5. Using a cylinder gauge, measure the cylinder bore diameter and calculate the honing allowance.

   Tip:

   Honing allowance = cylinder bore diameter - (piston diameter + oil clearance)

6. Finish the cylinder bore using the calculated value.

7. 

   Using a cylinder gauge, measure the cylinder bore diameter.

   Standard oil clearance
   0.019 to 0.052 mm (0.000748 to 0.00205 in.)

   Table 2. Text in Illustration

   *1	Thrust Direction
   *2	Axial Direction
   	Front