CYLINDER BLOCK REPAIR

CAUTION / NOTICE / HINT

Tech Tips


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

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

PROCEDURE


  1. BORE CYLINDER


    1. Prepare 4 new O/S pistons.

    2. A01XMM9E15
      Text in Illustration
      *a Distance

      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)
      95.471 to 95.481 mm (3.7587 to 3.7591 in.)
      Distance
      13.8 mm (0.543 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 oil clearance: 0.009 to 0.048 mm (0.000354 to 0.00189 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.

      Tech Tips

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

    6. Finish the cylinder bore using the calculated value.

    7. A01XHKHE06
      Text in Illustration
      *a Thrust Direction
      *b Axial Direction
      B001CHY Front

      Using a cylinder gauge, measure the cylinder bore diameter.

      Standard oil clearance
      0.009 to 0.048 mm (0.000354 to 0.00189 in.)