Re: 2.5L 200 HP rebuild/repair
Inspection/Remeasuring:
After inspecting the pistons a little closer I was able to remove enough unburned carbon to gather some valuable info. Piston's 1,2,3, and 5 are all .030" oversized. Piston 6 is .015" over. After borrowing a 3-4" mic from work I measured them at:
Piston #1: A - 3.521", B - 3.520"
Piston #2: A - 3.522", B - 3.519"
Piston #3: A - 3.523", B - 3.519"
Piston #5: A - 3.523", B - 3.519"
Piston #6: A - 3.509", B - 3.507"
The manual I have doesn't show the allowable tolerances for a .030 oversized piston, but it states a standard piston should be 3.494+/- .001" and a .015 oversized piston should be 3.509+/-.001". I am assuming a .030 oversized piston should be 3.524+/- .001". According to the manual I should be able to reuse pistons 3,5, and 6.
After measuring the pistons using the mic I decided to recheck my cylinder bores using the mic instead of the caliper. I measured each bore 5 times in various places and recorded the measurements.
Cylinder #1: 3.5135, 3.5135, 3.514, 3.510, 3.515
Cylinder #2: 3.513, 3.515, 3.511, 3.5135, 3.5185
Cylinder #3: 3.530, 3.530, 3.521, 3.530, 3.5265
Cylinder #4: 3.511, 3.519, 3.515, 3.516, 3.5125
Cylinder #5: 3.531, 3.5315, 3.535, 3.525, 3.531
Cylinder #6: 3.5145, 3.512, 3.515, 3.517, 3.513
I called a local machine shop on Friday to ask about pricing for boring, miking, and resleeving. I was quoted $38 to mic, $110 to bore one cylinder plus $50 for each additional cylinder on that side totalling around $420 for all 6. I didn't ask about honing pricing. Does this sound right? I am wondering if I could just hone each cylinder to achieve the desired overbore size, assuming that my measurements are correct and verified by the machine shop.
I also checked on the recirc line on the new block, and it appears to have the fitting on the top just like the other block. Both blocks have the exact same set up with a fitting on the side plugged/capped off. I will take a picture next time to confirm this as I am still confused as to just which fitting you are talking about.