Does anyone know what size ball hone and grit should be used to take the glazes off a 240d or 300d cylinder sleeve?

I've seen 89mm hones but I believe the cylinder diameter is 91mm.
I've also seen 120, 240 and 320 grit.

TIA

pete

RECOMMENDED CYLINDER BORE FINISH (generic).

Engine Cylinder Bore Honing

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84 300D, 82 Volvo 244Gl Diesel

Flex hones sizes refer to the bore size.
For a 91mm cylinder you buy a 91mm flex hone.
The actual hone will be larger then 91mm.
If they don't have a 91mm get the next size bigger.

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76 240 D. Bought in 1998 for $25.
85 300D. Got it for free with a bad engine. ( Sold )
60 Unimog 404. What was left of it, was given to me. Now powerd by 617A.
88 560 SEL. Bought without engine and trans. Now powerd by 617A.
67 250 SE. Cuope. For resto or sale.
64 220SE. For resto.

I take it that you are not going to change the sleeve, but hone the old one? Seems like the reasonable thing to do as long as it measures ok.

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1977 240D turbo

If I buy new sleeves,,do they need honing ? ty

Yes, I believe new sleeves are 89mm and need to be honed to 91mm.

My under standing is that the Ball Type Hones are used only to create the Ring seating cross hatched pattern in the Cylinder.
The Ball type Hones follow the shape of the Cylinder. If the Cylinder is oval it is going to stay oval after you use the Ball type Hone.
If you use a Ball type Hone in a Round Cylinder it stays round (if you do not over use it and if you use it properly).

You need another type of Cylinder Hone if you plan to enlarge the Bore and keep the bore Straight.

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84 300D, 82 Volvo 244Gl Diesel

Yes. To create the Cross Hatched ring seating pattern.

You can do it by hand with wet/Dry sand paper but it is a lot of work.

Please note that you nead to clean the Cylinder afterwards with soapy Wather.
Sraying it out with Brake Cleaner or another solovent will not get it as clean.

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84 300D, 82 Volvo 244Gl Diesel

I was told by a machine shop that new sleeves (in an OM617) need to be bored before honing.

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

yes new sleeves must be bored. fsm says so, and I know by experiance you do not hone 2 mm, it is too much to reasonably hone. Hones are meant to give the final surface finish. FSM qoutes .03mm to be left for final honing, and this is about .002", which is what I will normally leave for honing after boring.

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1977 240D turbo

Thanks for clearing that up - I guess it is a bit like people who confuse valve lapping with valve cutting / grinding. There are some wonderful videos on YouTube showing 5 year olds "grinding" away... what a cute way to bugger up your engine!

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Thanks for all the replies.

Does anyone know the exact size flex-hone/grit that is needed for a 240d or 300d cylinder sleeve?

It looks like this company was the first to create a flex hone.
Flex-Hone, Industrial Brushes, Wire Brushes

I'm going to get a 3 3/4 hone since it measures 95mm. The 3 1/2 flex hone measures 90mm. I haven't been able to find a flex home in between the 90 and 95mm hone.

I'm going to get the 240 grit. I want to take the glaze off the cylinder so new rings will seat.

If anyone thinks I should use a different size or different grit, please post your recommendations or experiences.

Thx

pete

Flex hones are very forgiving on the size, so no worries there. On grit, it is best to see what the ring manufacterer says. You are in the ballpark though if you can not find that info.

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1977 240D turbo

One more thought, when you are honing, run your drill slow and stroke up and down at a fair clip. Your goal is a 25 degree crosshatch. I put a piece of tape on the hone shaft so I do not go to far in. It will need to extend beyond the liner, but you will not have much room, so knowing where to stop on the down stroke is helpful.

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1977 240D turbo

Yes to the above.
A big variable speed Drill Motor (adjusted to turn slow) and lube the Cylinder walls. Best if the Drill Motor has 2 handles on it as the Drill Motor is going to try to twist out of your hands.

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84 300D, 82 Volvo 244Gl Diesel