Procedures

2TR-FE ENGINE MECHANICAL: CYLINDER BLOCK: REPAIR

HINT
* Bore all 4 cylinders to fit the O/S piston outside diameter.
* Replace all the piston rings with ones to match the O/S pistons.

1. BORE CYLINDER

(a) Prepare 4 new O/S pistons.

(b) 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):

95.441 to 95.471 mm (3.758 to 3.759 in.)

Distance:

13.8 mm (0.543 in.)

Text in Illustration





(c) Calculate the amount each cylinder is to be rebored as follows.

HINT
* Size to be rebored = P + C - H
P = Piston diameter
C = Piston oil clearance: 0.013 to 0.036 mm (0.000512 to 0.00142 in.)
H = Allowance for honing: 0.02 mm (0.000787 in.) or less

(d) Bore and hone the cylinders to the calculated dimensions.

NOTICE:
Excess honing will destroy the finished roundness.

(e) Using a cylinder gauge, measure the cylinder bore diameter and calculate the honing allowance.

HINT
Honing allowance = cylinder bore diameter - (piston diameter + oil clearance)

(f) Finish the cylinder bore using the calculated value.

(g) Using a cylinder gauge, measure the cylinder bore diameter at position A in the thrust and axial directions.





Standard oil clearance:

0.019 to 0.052 mm (0.000748 to 0.00205 in.)

Text in Illustration