--------------CHAPTER1
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Measure lengthwise:
A to B and C to D and compare dimensions,
variances between the readings will indicate
"taper".
Measure crosswise:
C to D and compare dimensions lengthwise.
A
to
B variances will indicate an
out-of-round
condition.
Specifications:-
Taper
of cylinder bore:
repair limit-0.001
in
(0.025mm)
wear
limit
-0.005
in
(0.127mm)
Cylinder bore out of round:
repair
limit-0.0015
in (0.03mm)
wear
limit-0.005
in
(0.127mm)
Cylinder
bore
diameter:
4.4007-4.4032
in (111.778-111.841 mm).
2. Where only minor imperfections exist and
bores are to specification, hone the bores
prior to installing
new
piston rings, pro-
vided piston to bore clearance does not
exceed 0.0065 in (0.165mm).
3. If cylinder bores are outside the specifica-
tion they should be bored or honed, to fit
the next oversize piston. The finished
bore size can
be
determined by measur-
ing piston diameter at right angles to the
piston pin and adding the appropriate pis-
ton to bore clearance.
4. Oversize pistons available:
0.004
in
(0.10mm)
0.020
in
(0.51 mm)
0.040 in (1.0mm)
5. Bores to take 0.004 in (0.10mm) oversize
pistons need only
be
honed using a rigid
hone with a grit size
of
150-220.
Clean
thoroughly after boring and honing.
6. Sleeving
of
the cylinder bores becomes
expedient
when:-
1, Oil consumption is high due to porosity.
2, Replacing sleeves, installed
in
service.
3, Cylinder bore is damaged beyond
re-
boring limits.
NOTE:
When reconditioning engines
equipped with sleeves, use only standard
or
0.004 in (0.1016mm) oversize pistons
23
SLEEVING - BORING AND
HONING
40
R1-37
Cylinder
Block
Sleeving
1.
Measure the outside diameter (1)
of
the
sleeve
in
several places and average the
dimension. Counter bore the cylinder
block (see
step
2) using the average di-
mension to obtain a press fit between
bore and sleeve. Interference
of
sleeve to
the cylinder bore to
be
0.001-0.003
in
(0.025-0.076mm), Figure 40.
2. Counter bore to a depth
of
8.26 in
(209mm) from the block face, surface fin-
ish of the bore is not to exceed (80 mi-
crons). Leave a step
at
the bottom
of
the
bore a minimum
of
0.180-0.200
in
(4.572-5.080mm), allowing for run out of
chamfers.
3. Bore through diameter to the diameter
of
4.454-4.456
in
(114.3-116.0mm).
4. Clean the cylinder bores and thoroughly
dry.
5. Grease the sleeve with
ESA-MIC75-B
or
similar and press the sleeve home to the
lip in
the
bore. The top of the sleeve
should protrude through the top
of
the
block
0.005-0.040
in
(0.127-1.0mm).
6.
Bore the sleeve to:
4.3985-4.400
in
(110.00-111. 76mm).
7.
Skim the block face and top
of
sleeves to
achieve the specified flatness of
0.003
in
(0.08mm)
in
any
6 in (152mm),
0.001
in
(0.03mm)
in
any
1 in (25.4mm).
A chamfer
in
the internal diameter
at
the
top
of
the sleeve to 45°x0.020
in
(0.5mm)
should be maintained to prevent piston
damage on re-assembly.
8.
Break the sharp edge at the bottom
of
the
sleeve prior to honing.
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