Usage:
The FLEX-HONE can be used to remove the glaze and make the crosshatch pattern in the cylinder bores of a 3204 and 3208 Engine while the engine is installed. The correct procedure for the use of the FLEX-HONE is given in GUIDELINE FOR REUSABLE PARTS, PISTON AND CYLINDER LINERS, Form No. SEBF8001-01.
The use of the FLEX-HONE will make a grit (sand-like particles). If the grit is not completely removed after the hone operation, it can cause rapid wear to the piston rings, cylinder walls and crankshaft. It is also possible to damage the crankshaft and the hone, if the hone is pushed too far into the cylinder bore.
Below are some cautions and procedures to use when the FLEX-HONE is used with the engine installed and the crankshaft in place.
1. Use engine oil or solvent on the FLEX-HONE for lubrication. This holds the grit particles until they can be cleaned off. Never use the FLEX-HONE without lubrication.
2. It can be difficult to use the FLEX-HONE in the rear bores on some engine installations. For this problem, it is possible to use the hone from the bottom side of the engine or to drive the hone from the short end. It can also be necessary to cut the hone to a shorter length to completely remove the glaze on the cylinder wall and not cause damage to the crankshaft.
3. Put tape, paper or cardboard strips around the crankshaft journals to keep the grit and solvents away from the main bearings. Put plastic plugs in the crankshaft lubrication holes and use a brake rotochamber boot or rubber ball (cut in half) in the bottom of the cylinder bore to keep the grit from the crankshaft.
4. After the FLEX-HONE operation, use a strong solution of detergent and water and a soft nylon brush to clean the grit from the cylinder bores. The 1P5574 Brush is available for this operation.
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Solvents, diesel fuel, oil or other cleaners will not remove this grit.
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To be sure the bores are clean, check with a lint-free white cloth. If the cloth shows gray or dark, the bore must be cleaned again.
5. After the bores are cleaned, carefully remove the tape, paper or cardboard strips from the crankshaft journals. Wash these areas thoroughly with soap and water and dry with air or clean shop towels. To be sure the journals are clean, check with a lint-free white cloth.
6. After the crankshaft is clean, remove the plastic plugs from the lubrication holes and put engine oil on all surfaces to protect them until assembly.
The above procedures are adaptable to all 1100, 3100, 3204, and 3208 Engines when access is possible. In some applications it is not possible to use the FLEX-HONE on the rear cylinders from either the top or bottom. For these units it will be necessary to remove the engine.