ENGINE UNIT > REPAIR

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1. INSPECT BORE CYLINDER

HINT:
  1. Bore all the 4 cylinders for the O/S piston outside diameter.
  2. Replace all the piston rings with ones to match the O/S pistons.

  1. Keep 4 new O/S pistons.

    Piston diameter:
    O/S 0.50
    		O/S 0.75
    		O/S 1.00
    96.42 to 96.70 mm (3.7960 to 3.8070 in.)
    		96.67 to 96.95 mm (3.8058 to 3.8169 in.)
    		96.92 to 97.20 mm (3.8157 to 3.8267 in.)



    A060217E01

  1. Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston head.

    Distance:
    65.00 to 65.06 mm (2.5591 to 2.5614 in.)

  1. 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: 0.070 to 0.090 mm (0.0028 to 0.0035 in.)
    H = Allowance for honing: 0.02 mm (0.0008 in.) or less

  1. Bore and hone the cylinders to calculated dimensions.

    Maximum honing:
    0.02 mm (0.0008 in.)

    NOTICE:
    Excess honing will destroy the finished roundness.