S-69
05-E3B, 05-E3BG, WSM
DIESEL ENGINE
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
W10343890
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.5 mm (0.02 in.)
NOTE
■
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
W10344480
Cylinder I.D.
Factory
spec.
D1005-E3B / E3BG
76.000 to 76.019 mm
2.9922 to 2.9929 in.
D1105-E3B / E3BG
D1105-T-E3B
D1305-E3B / E3BG
V1505-E3B / E3BG
V1505-T-E3B
78.000 to 78.019 mm
3.0709 to 3.0716 in.
Allowable
limit
D1005-E3B / E3BG
76.15 mm
2.998 in.
D1105-E3B / E3BG
D1105-T-E3B
D1305-E3B / E3BG
V1505-E3B / E3BG
V1505-T-E3B
78.15 mm
3.077 in.
(A) Top
(B) Middle
(C) Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
Oversized
cylinder liner
I.D.
Factory
spec.
D1005-E3B / E3BG
76.500 to 76.519 mm
3.0119 to 3.0125 in.
D1105-E3B / E3BG
D1105-T-E3B
D1305-E3B / E3BG
V1505-E3B / E3BG
V1505-T-E3B
78.500 to 78.519 mm
3.0906 to 3.0912 in.
Allowable
limit
D1005-E3B / E3BG
76.65 mm
3.018 in.
D1105-E3B / E3BG
D1105-T-E3B
D1305-E3B / E3BG
V1505-E3B / E3BG
V1505-T-E3B
78.65 mm
3.096 in.
Finishing
Hone to 1.2 to 2.0
μ
m R max.
∇∇∇
(48 to 78 in.
μ
in. R max.)
(1) Cylinder I.D. (Before Correction)
(2) Cylinder I.D. (Oversize)
KiSC issued 12, 2007 A
