28. Cylinder Honing

CAUTION: DO NOT ALLOW HONE TO COME OUT OF CYLINDER BORE WHILE IT IS TURNING. THE STONES COULD BE RELEASED AND CAUSE INJURY.

1. Hone bores to within 0.005 mm (0.0002 inch) of desired size using 120-150 grit stones.
2. Finish hone to desired size by removing 0.005 mm (0.0002 inch) left in second step using 320 grit stones.

CYLINDER BORE
(8) 85.975 - 85.985 mm (3.3848 - 3.3852 inch)
(99) 85.985 - 85.995 mm (3.3852 - 3.3856 inch)
(00) 85.995 - 86.005 mm (3.3856 - 3.3860 inch)
(01) 86.005 - 86.015 mm (3.3860 - 3.3864 inch)
(02) 86.015 - 86.025 mm (3.3864 - 3.3868 inch)
(7 + 0.5) 86.465 - 86.475 mm (3.4041 - 3.4045 inch)

PISTON SIZE
(8) 85.940 - 85.950 mm (3.3834 - 3.3838 inch)
(99) 85.950 - 85.960 mm (3.3838 - 3.3842 inch)
(00) 85.960 - 85.970 mm (3.3842 - 3.3846 inch)
(01) 85.970 - 85.980 mm (3.3846 - 3.3850 inch)
(02) 85.980 - 85.990 mm (3.3850 - 3.3854 inch)
(7 + 0.5) 86.430 - 86.440 mm (3.4027 - 3.4031 inch)





IMPORTANT: Make sure crankshaft pulley/damper keyway is at 3 or 9 o'clock position to prevent damage of crankshaft connecting rod journals during honing.

a. Hone the cylinder bore using a 10W-30 or 5W-30 weight motor oil and flex hone (SA9171E).
b. Make sure the flex hone is slowly rotating upon entry and removal from cylinder bore.

IMPORTANT: The recommended speed of the flex hone is 150 - 200 rpm. Do not use air pressure driven or high-speed tools.

c. Use 60 strokes per minute. Honing time should be approximately 20 seconds or 20 strokes per cylinder to develop a 45 - 50° (included angle) honing cross-hatch. One "stroke" consists of a full downward and upward motion of the flex hone in the cylinder bore.
d. Thoroughly scrub cylinder bores after honing with a scrub brush, a strong solution of hot water and Tide (R) powder laundry detergent (or equivalent). Thoroughly rinse with hot clean water (high-pressure, if available).

IMPORTANT: If the cylinder bores are not thoroughly cleaned, the residual grit from the honing stones will wear out the piston rings and cylinder bores extremely fast, resulting in oil consumption. Never use solvent to clean cylinder bores; it will only redistribute the grit on the cylinder walls; detergent and hot water will carry the grit away.

e. Dry the cylinder bores and wipe them with a clean white towel saturated with engine oil. Dark residual grit on the towel after wiping the cylinder bore indicates the bores are not clean. The cleaning process in step e must be repeated until the towel is free of all dark residual grit.