CYLINDER BLOCK REPAIR

CAUTION / NOTICE / HINT

PROCEDURE

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   BORE CYLINDER

   
   

   1. Prepare 4 new O/S pistons.

   2. 

      *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)
      86.451 to 86.486 mm (3.4036 to 3.4050 in.)

      Distance
      11.4 mm (0.449 in.)

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

      Table 1. Size to be rebored = P + C - H

      P	Piston diameter
      C	Piston oil clearance: 0.004 to 0.052 mm (0.000157 to 0.00205 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.

   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. 

      *a	Thrust Direction
      *b	Axial Direction
      *c	10 mm (0.394 in.)
      *d	70 mm (2.76 in.)
      	Front

      Using a cylinder gauge, measure the cylinder bore diameter.

      Standard oil clearance
      0.004 to 0.052 mm (0.000157 to 0.00205 in.)