Honing or Reboring Cylinders

WARNING: This page is about a different car, the 2004 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 also be rebored at the same time.
Select oversized piston according to amount of cylinder wear.
Oversize piston specification

Fig 1: Oversize Piston Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.
Using micrometer, measure piston diameter.
Calculate cylinder bore diameter to be rebored as follows.
D = A + B - C

D: Cylinder bore diameter to be rebored

A: Piston diameter as measured

B: Piston clearance = 0.02 - 0.04 mm (0.0008 - 0.0015 in.)

C: Allowance for honing = 0.02 mm (0.0008 in.)

Fig 2: Measuring Piston Diameter Using Micrometer
Courtesy of SUZUKI OF AMERICA CORP.
Rebore and hone cylinder to calculated dimension.
NOTE: Before reboring, install all main bearing caps in place and tighten to specification to avoid distortion of bearing bores.
Measure piston clearance after honing.