EM-103ENGINE MECHANICAL Cylinder Block
BORING OF CYLINDERS
HINT:
• Bore all five (1 PZ) or six (1 HZ and 1 HD-T) cylinders for
the oversized piston outside diameter.
• Replace the piston rings with ones to match the over-
sized pistons.
1. KEEP OVERSIZED PISTONS
Oversized piston diameter:
O/S0.50 94.45-94.48 mm
(3.7185-3.7197 in.)
2. CALCULATE AMOUNT TO BORE CYLINDER
(a) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, at the
indicated distance from the piston head.
Distance:
1 PZ and 1 HZ 58.6 mm (2.3071 in.)
1 HD-T 65.7 mm (2.5866 in.)
(b) Calculate the amount each cylinder is to be rebored as
follows:
Size to be rebored = P + C- H
P = Piston diameter
C = Piston oil clearance
0.04-0.06 mm (0.0016-0.0024 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
3. BORE AND HONE CYLINDERS TO CALCULATED
DIMENSIONS
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE: Excess honing will destroy the finished
roundness.
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