Honing or Reboring Cylinders

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

When any cylinder needs reboring, all other cylinders must be rebored at the same time.
Select oversized piston according to amount of cylinder wear.
Oversize piston specification

Fig 1: Oversize Piston Specification Chart
Courtesy of SUZUKI OF AMERICA CORP.
Using micrometer, measure piston diameter.

Fig 2: Measuring Piston Diameter (Oversize)
Courtesy of SUZUKI OF AMERICA CORP.
Calculate cylinder bore diameter to be rebored as follows.
1. D = A + B - C
2. D: Cylinder bore diameter to be robored.
3. A: Piston diameter measured.
4. B: Piston clearance = 0.02 - 0.04 mm (0.0008-0.0016 in.)
5. C: Allowance for honing = 0.02 mm (0.0008 in.)
Rebore and hone cylinder to calculated dimension.
NOTE: Before reboring, install lower crankcase and tighten to specification to avoid distortion of bearing bores.
Measure piston clearance after honing.