CYLINDER BLOCK REPAIR

PROCEDURE


  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. A01LDTJC05
      *a Size Mark
      *b Piston Pin Hole Inside Diameter Mark
      *c Front Mark (Arrow)
      *d 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
      63 mm (2.48 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.