S5 Workshop Manual Engine
3) If the cylinder exceeds the specified cylindricity or roundness after inspection, or
cylinder wall has serious abrasion or scratch, re-bore the cylinder and grind cylinder
body. And install new piston and piston ring.
Standard Value:
Cylinder Bore:85 + 0.03 mm
Cylindricity or roundness of the bore: maximum 0.01 mm
4) If the top of cylinder has projected mark or deposited carbon, use a reamer or
No.600 sand paper to remove them.
5) If the re-bored cylinder hole is excessive, keep the specified clearance between
piston and cylinder, and make sure that all used pistons have the same size. Outer
diameter of piston is measured on 12 mm above the bottom of piston skirt of the
piston and measured along the thrust force.
Clearance between piston and cylinder:
0.02 - 0.04 mm
6) Inspect whether there is damage or crack.
7) Inspect the flatness of upper surface of cylinder body. If it exceeds limit value,
grind it to minimum limit value or replace it.
Standard value:
Cylinder body flatness:
Max. 0.05 mm
Maintenance limited value:
Cylinder body flatness 0.1 mm
Notes:
■ When assembly cylinder head, the grinding size of less than 0.2 mm is allowed.
4. Repair Cylinder
1) For cylinder repair, it is necessary to re-bore the cylinder hole, and then install a
new cylinder sleeve.
Notes:
■ To avoid deformation due to high temperature during grinding, cylinder hole should
be bored according to ignition sequence.
2) Grind cylinder and modify it to suitable size (outer diameter of piston + clearance
between cylinders).
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