Cylinder Block Assembly: Service and Repair

CYLINDER BORING
1. Determine the oversize piston on the basis of the largest bore cylinder.
2. Two types of oversize pistons (0.50 mm and 1.00 mm) are available. The standard measuring points for the piston outside diameter are at the positions shown in the illustration. Based on the measured piston outside diameter, calculate the boring finish dimension. [Boring finish dimension] = [Piston outside diameter] + [0.02 - 0.04 mm (0.0008 - 0.0016 inch) clearance to cylinder] - [0.02 mm (0.0008 inch) honing margins
4. Bore each cylinder to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston outside diameter + clearance between piston outside diameter and cylinder).
6. Check the piston to cylinder clearance. The standard value is 0.02 - 0.04 mm (0.0008 - 0.0016 inch).