Cylinder Block (W/ Glow Plug Controller) Repair

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Kd-Ftv Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. BORE CYLINDER

Cylinder Block (W/ Glow Plug Controller) -- Repair



1. BORE CYLINDER
HINT:
  1. Bore all 4 cylinders for the O/S piston outside diameter.
  2. Replace all the piston rings with ones to match the O/S pistons.

  1. Prepare 4 new O/S pistons.

    Standard Piston Diameter:
    Item
    		Specified Condition
    O/S 0.50
    		96.42 to 96.45 mm (3.796 to 3.797 in.)
    O/S 0.75
    		96.67 to 96.70 mm (3.806 to 3.807 in.)
    O/S 1.00
    		96.92 to 96.95 mm (3.816 to 3.817 in.)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Block (W/ Glow Plug Controller) Repair

  1. Using a micrometer, measure the piston diameter according to the following conditions: 1) measure at a right angle to the piston center line, and 2) measure at the indicated distance from the piston head.

    Distance:
    63.5 mm (2.50 in.)
    Text in Illustration
    *1
    		Size Mark
    *2
    		Piston Pin Hole Inside Diameter Mark
    *3
    		Front Mark (Arrow)
    *4
    		Distance

  1. Calculate how much each cylinder needs to be rebored:

    Size to be rebored:
    Size to be rebored = P + C - H
    P = Piston diameter
    C = Piston clearance: 0.07 to 0.09 mm (0.00276 to 0.00354 in.)
    H = Allowance for honing: 0.02 mm (0.000787 in.) or less

  1. Bore and hone the cylinders to the calculated dimensions.

    Maximum honing:
    0.02 mm (0.000787 in.)
    NOTICE:
    Excess honing will destroy the finished roundness.