Ford Corsar Repair Manual page 132

ENGINE OVERHAUL -Inspection-
I
CA20E
I
The size to which cylinders must be honed is, determined
by adding piston-tocylinder clearance to the piston skirt
diameter "A".
Dimension "a":
45.0 mm (1.772 in)
Rebored size calculation
D
=
A
+
B
-
C =
A
+
[0.005 to 0.025 mm
(0.0002 to 0.0010 in)]
where,
D
:
Honed diameter
A : Skirt d,iameter as measured
B : Pistotj-to-wall clearance
C
:
Machining allowance
0.02 mm (0.0008 in)
3.
Install main bearing caps in place, and tighten to the specified
torque to prevent distortion of the cylinder bores in final
assembly.
4. Cut cylinder bores in the order of 2-4-1-3.
a
Do not cut too much out of the cylinder bore
a t a
time.
Cut only 0.05 mm (0.0020 in) or so in diameter a t a time.
5. Hone the cylinders to the required size referring to S.D.S.
6. Measure the finished cylinder bore for out-of-round and
taper.
a
Measurement of a just machined cylinder bore requires
utmost care since
it
i s expanded by cutting heat.
PISTON TO CYLINDER WALL CLEARANCE
Using micrometer
1. Measure piston and cylinder bore diameter.
Piston diameter "A":
Refer to S.D.S.
Measuring point "a" (Distance from the bottom):
45.0 mm (1.772 in)
2. Check that piston clearance is within the specification.
Piston clearance:
0.025
-
0.045 mm (0.0010
-
0.0018 in)
Using feeler gauge
Measure the extracting force by pulling feeler gauge straight
upward.
Feeler gauge thickness:
0.04 mm (0.0016 in)
Extracting force:
2.0
-
14.7 N (0.2
-
1.5 kg, 0.4
-
3.3 Ib)