{"id":2315,"date":"2023-11-08T19:16:12","date_gmt":"2023-11-08T19:16:12","guid":{"rendered":"https:\/\/mbci.mackuz.ovh\/?p=2315"},"modified":"2023-11-08T19:16:12","modified_gmt":"2023-11-08T19:16:12","slug":"checking-drilling-and-honing-cylinder-bores","status":"publish","type":"post","link":"https:\/\/mbci.mackuz.ovh\/index.php\/2023\/11\/08\/checking-drilling-and-honing-cylinder-bores\/","title":{"rendered":"Checking, drilling and honing cylinder bores"},"content":{"rendered":"

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01\u2014110 Checking, drilling and honing cylinder bores<\/div>\n<\/div>\n<\/td>\n
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Data<\/strong><\/div>\n<\/div>\n<\/td>\n
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Group number1<\/sup>)<\/div>\n<\/div>\n<\/td>\n
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0<\/div>\n<\/div>\n<\/td>\n
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1<\/div>\n<\/div>\n<\/td>\n
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2<\/div>\n<\/div>\n<\/td>\n
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Standard dimension 86.0<\/div>\n<\/div>\n<\/td>\n
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piston dia.<\/div>\n
cylinder dia.<\/div>\n<\/div>\n<\/td>\n
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85.970-85.982<\/div>\n
85.998-86.008<\/div>\n<\/div>\n<\/td>\n
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85.980-85.992<\/div>\n
86.008-86.018<\/div>\n<\/div>\n<\/td>\n
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85.990-86.002<\/div>\n
86.019-86.028<\/div>\n<\/div>\n<\/td>\n
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Repair stage 1 + 0.5<\/div>\n<\/div>\n<\/td>\n
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piston dia.<\/div>\n
cylinder dia.<\/div>\n<\/div>\n<\/td>\n
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86.470-86.482<\/div>\n
86.498-86.508<\/div>\n<\/div>\n<\/td>\n
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86.480-86.492<\/div>\n
86.508-86.518<\/div>\n<\/div>\n<\/td>\n
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86.490-86.502<\/div>\n
86.519-86.528<\/div>\n<\/div>\n<\/td>\n
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Repair stage 2 + 1.0<\/div>\n<\/div>\n<\/td>\n
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piston dia.<\/div>\n
cylinder dia.<\/div>\n<\/div>\n<\/td>\n
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86.970-86.982<\/div>\n
86.998-86.008<\/div>\n<\/div>\n<\/td>\n
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86.980-86.992<\/div>\n
87.008-87.018<\/div>\n<\/div>\n<\/td>\n
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86.990-86.002<\/div>\n
87.019-87.028<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/td>\n<\/td>\n<\/tr>\n
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Decisive for association is the smallest measured cylinder dia. and the largest measured piston dia.<\/div>\n<\/div>\n<\/td>\n
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Max. wear limit in driving or transverse direction of cylinder bores at <\/em>upper reversing point of 1st piston ring<\/div>\n<\/div>\n<\/td>\n
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0,10<\/div>\n<\/div>\n<\/td>\n
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When new<\/div>\n<\/div>\n<\/td>\n
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0,025-0,035<\/div>\n<\/div>\n<\/td>\n
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Piston clearance<\/div>\n<\/div>\n<\/td>\n
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Wear limit<\/div>\n<\/div>\n<\/td>\n
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0,08<\/div>\n<\/div>\n<\/td>\n
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Machining tolerances<\/strong><\/div>\n<\/div>\n<\/td>\n
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Permissible deviation (radial distance) from cylinder shape<\/div>\n<\/div>\n<\/td>\n
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When new<\/div>\n<\/div>\n<\/td>\n
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0,007<\/div>\n<\/div>\n<\/td>\n
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Wear limit<\/div>\n<\/div>\n<\/td>\n
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0,025<\/div>\n<\/div>\n<\/td>\n
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Permissible deviation from square with reference to cylinder height<\/div>\n<\/div>\n<\/td>\n
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0,05<\/div>\n<\/div>\n<\/td>\n
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Mean height of roughness<\/div>\n<\/div>\n<\/td>\n
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0,002-0,004<\/div>\n<\/div>\n<\/td>\n
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Permissible height of waviness<\/div>\n<\/div>\n<\/td>\n
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50 % of roughness<\/div>\n<\/div>\n<\/td>\n
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Chamfer of cylinder bores<\/div>\n<\/div>\n<\/td>\n
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see fig. point 2<\/div>\n<\/div>\n<\/td>\n
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Conventional tools<\/strong><\/div>\n<\/div>\n<\/td>\n
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Inside measuring instrument for 50\u2014150 mm dia., with 0.01 mm readout and measuring point pressure relief<\/div>\n<\/div>\n<\/td>\n
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e.g. made by Hommel Sunnen GRM-2125<\/div>\n<\/div>\n<\/td>\n
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Handel, 5000 Koln 71<\/div>\n<\/div>\n<\/td>\n
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Note<\/strong><\/div>\n<\/div>\n<\/td>\n
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In particular for a complaint concerning „excessive oil consumption” a measurement of the cylinder bores is essential in addition to a visual inspection.<\/div>\n<\/div>\n<\/td>\n
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01.2-110\/1 F3<\/div>\n<\/div>\n<\/td>\n
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1 Measure the cleaned cylinder bores with an internal tester at measuring points 1, 2 and 3 in longitudinal direction A (piston pin axis) and in cross direction B.<\/div>\n<\/div>\n<\/td>\n
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When the pistons are installed measuring point 3 will be just barely above the piston, which must be at BDC.<\/div>\n<\/div>\n<\/td>\n
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\"m110<\/div>\n<\/td>\n
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a top reversing point of first piston ring<\/div>\n
b BDC of piston<\/div>\n
c bottom reversing point of oil scraper ring<\/div>\n<\/div>\n<\/td>\n
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The group number punched into crankcase (arrow), matches the group number of the pistons installed as standard equipment.<\/div>\n
On used engines, the original cylinder dia. shows up after thorough cleaning of top land zone.<\/div>\n
The difference in diameter of dimension shown on top land zone and the dimension at measuring point 1 generally indicates the respective max. wear.<\/div>\n<\/div>\n<\/td>\n
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In the event of repairs, hone cylinder bores according to dimensions of available pistons plus piston clearance.<\/div>\n
The processing machines used for boring (pre-honing), finish-honing and polishing should be set in accordance with respective operating instructions.<\/div>\n<\/div>\n<\/td>\n
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Upon boring, the cylinder bores should be chamfered at upper cylinder end according to drawing.<\/div>\n
The lower cylinder end should remain sharp edged without burr.<\/div>\n<\/div>\n<\/td>\n
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\"m110<\/div>\n<\/td>\n
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01.2-110\/2 F3<\/div>\n<\/div>\n<\/td>\n
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01\u2014120 Grinding crankcase mating surface<\/div>\n<\/div>\n<\/td>\n
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Data<\/strong><\/div>\n<\/div>\n<\/td>\n
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\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
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Height of new crankcase<\/div>\n<\/div>\n<\/td>\n
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213.1-213.2<\/div>\n<\/div>\n<\/td>\n
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Min. height after removal of necessary material<\/div>\n<\/div>\n<\/td>\n
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212.8<\/div>\n<\/div>\n<\/td>\n
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Permissible deviation from parallel of upper parting surface in relation to lower parting surface in longitudinal direction<\/div>\n<\/div>\n<\/td>\n
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0,1<\/strong><\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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Permissible deviation from flatness of upper parting surface<\/div>\n<\/div>\n<\/td>\n
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0,03<\/div>\n<\/div>\n<\/td>\n
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Mean height of roughness of upper parting surface<\/div>\n<\/div>\n<\/td>\n
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0,005-0,020<\/div>\n<\/div>\n<\/td>\n
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Leak test with 1.5 bar air gauge pressure under water. Permissible leak rate in cc\/min<\/div>\n<\/div>\n<\/td>\n
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10<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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Chamfer of cylinder bores<\/div>\n<\/div>\n<\/td>\n
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see note<\/div>\n<\/div>\n<\/td>\n
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Piston spacing in relation to parting surface<\/strong><\/div>\n<\/div>\n<\/td>\n
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Engines with normal compression<\/div>\n<\/div>\n<\/td>\n
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USA version and low compression<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/td>\n<\/td>\n<\/tr>\n
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Distance between piston crown and crankcase mating surface<\/div>\n<\/div>\n<\/td>\n
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Standard size piston Below<\/div>\n<\/div>\n<\/td>\n
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min. 0.20 max.0.70<\/div>\n<\/div>\n<\/td>\n
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above 0.25 below 0.15<\/div>\n<\/div>\n<\/td>\n
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Oversizes + 0.5 and 1.0<\/div>\n<\/div>\n<\/td>\n
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Below<\/div>\n<\/div>\n<\/td>\n
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min. 1.0 max. 1.5<\/div>\n<\/div>\n<\/td>\n
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below<\/div>\n<\/div>\n<\/td>\n
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min. 0.55 max.0.95<\/div>\n<\/div>\n<\/td>\n
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Conventional tools<\/strong><\/div>\n<\/div>\n<\/td>\n
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Surface grinding machine<\/div>\n<\/div>\n<\/td>\n
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e.g. made Scledum,<\/div>\n<\/div>\n<\/td>\n
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by Ruaro u. type RTY<\/div>\n<\/div>\n<\/td>\n
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Fi.,<\/div>\n<\/div>\n<\/td>\n
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Schio\/ltaly<\/div>\n<\/div>\n<\/td>\n
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Knife-edge straightedge approx.<\/div>\n<\/div>\n<\/td>\n
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750 mm<\/div>\n<\/div>\n<\/td>\n
\n
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long<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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<\/div>\n<\/div>\n

 <\/td>\n

<\/td>\n<\/tr>\n
<\/td>\n\n
\n
Note<\/strong><\/div>\n<\/div>\n<\/td>\n
\n
\"m110<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
\n
Chamfer cylinder bores after grinding.<\/div>\n
Adjust valve timing (05\u2014215), if crankcase mating surface has been machined.<\/div>\n<\/div>\n<\/td>\n
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<\/div>\n<\/div>\n

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<\/td>\n<\/tr>\n
<\/td>\n\n
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01.2-120\/1 F3<\/div>\n<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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 <\/p>\n","protected":false},"excerpt":{"rendered":"

    01\u2014110 Checking, drilling and honing cylinder bores   Data         Group number1)   0 1 2 Standard dimension 86.0 piston dia. cylinder dia. 85.970-85.982 85.998-86.008 85.980-85.992 86.008-86.018 85.990-86.002 86.019-86.028 Repair stage 1 + 0.5 piston dia. cylinder dia. 86.470-86.482 86.498-86.508 86.480-86.492 86.508-86.518 86.490-86.502 86.519-86.528 Repair stage 2 + 1.0 piston dia. cylinder dia. 86.970-86.982 86.998-86.008 86.980-86.992 87.008-87.018 86.990-86.002 87.019-87.028   Decisive for association is the smallest measured cylinder dia. and the largest measured piston dia.   Max. wear limit in driving or transverse direction of cylinder bores at upper reversing point of 1st piston ring 0,10   When new 0,025-0,035   Piston clearance   Wear limit 0,08   Machining tolerances   Permissible deviation (radial distance) from cylinder shape When new 0,007   Wear limit 0,025   Permissible deviation from square with reference to cylinder height   0,05 Mean height of roughness   0,002-0,004 Permissible height of waviness   50 % of roughness Chamfer of cylinder bores   see fig. point 2 Conventional tools     Inside measuring instrument for 50\u2014150 mm dia., with 0.01 mm readout and measuring point pressure relief e.g. made by Hommel Sunnen GRM-2125 Handel, 5000 Koln 71   Note   In particular for a complaint concerning „excessive oil consumption” a measurement of the cylinder bores is essential in addition to a visual inspection.   01.2-110\/1 F3         1 Measure the cleaned cylinder bores with an internal tester at measuring points 1, 2 and 3 in longitudinal direction A (piston pin axis) and in cross direction B.   When the pistons are installed measuring point 3 will be just barely above the piston, which must be at BDC. a top reversing point of first piston ring b BDC of piston c bottom reversing point of oil scraper ring The group number punched into crankcase (arrow), matches the group number of the pistons installed as standard equipment. On used engines, the original cylinder dia. shows up after thorough cleaning of top land zone. The difference in diameter of dimension shown on top land zone and the dimension at measuring point 1 generally indicates the respective max. wear.   In the event of repairs, hone cylinder bores according to dimensions of available pistons plus piston clearance. The processing machines used for boring (pre-honing), finish-honing and polishing should be set in accordance with respective operating instructions.   Upon boring, the cylinder bores should be chamfered at upper cylinder end according to drawing. The lower cylinder end should remain sharp edged without burr. 01.2-110\/2 F3         01\u2014120 Grinding crankcase mating surface   Data   Height of new crankcase 213.1-213.2 Min. height after removal of necessary material 212.8 Permissible deviation from parallel of upper parting surface in relation to lower parting surface in longitudinal direction 0,1 Permissible deviation from flatness of upper parting surface 0,03 Mean height of roughness of upper parting surface 0,005-0,020 Leak test with 1.5 bar air gauge pressure under water. Permissible leak rate in cc\/min 10 Chamfer of cylinder bores see note Piston spacing in relation to parting surface   Engines with normal compression USA version and low compression   Distance between piston crown and crankcase mating surface Standard size piston Below min. 0.20 max.0.70 above 0.25 below 0.15 Oversizes + 0.5 and 1.0 Below min. 1.0 max. 1.5 below min. 0.55 max.0.95   Conventional tools             Surface grinding machine     e.g. made Scledum, by Ruaro u. type RTY Fi., Schio\/ltaly Knife-edge straightedge approx. 750 mm long           Note Chamfer cylinder bores after grinding. Adjust valve timing (05\u2014215), if crankcase mating surface has been machined.   01.2-120\/1 F3            <\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_crdt_document":"","footnotes":""},"categories":[29,27],"tags":[],"class_list":["post-2315","post","type-post","status-publish","format-standard","hentry","category-engine-removal-and-installation-ventilation-cran","category-m110"],"aioseo_notices":[],"featured_image_src":null,"author_info":{"display_name":"mackuz","author_link":"https:\/\/mbci.mackuz.ovh\/index.php\/author\/mackuz\/"},"_links":{"self":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2315","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/comments?post=2315"}],"version-history":[{"count":1,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2315\/revisions"}],"predecessor-version":[{"id":2316,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2315\/revisions\/2316"}],"wp:attachment":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/media?parent=2315"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/categories?post=2315"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/tags?post=2315"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}