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Honing – Plateau Honing – Diamond Honing

Honing procedures
When cylinders are bored to oversize, they are generally bored or rough honed to within about .0025″ to .003″ of final size to allow for finish honing. The finish honing step removes the fractured and torn metal created by the boring process, and produces the kind of surface finish and crosshatch. After this process the cylinder block is then Honed. this can be the old style normal honed, plateau honed or diamond honed

 The short and sweet version of  all 3 processes  


Most OEMs and ring manufacturers say the angle of the scratches in the crosshatch pattern should be about 45° to each other, or about 22° to 32° to the horizontal deck surface.  You must refer to the OEM  manual specification to confirm your crosshatch requirements.The crosshatch angle should be the same throughout the length of the cylinder and not flatten out at either end.

If the crosshatch angle is too steep

  •  the rings can pump oil or experience excessive rotation which will accelerate wear in the rings and piston lands.

If the crosshatch angle is too shallow,

  • it can have a ratcheting effect as the rings pass over the valleys, preventing the rings from receiving proper lubrication.

* note * The old Style Flexi Hone or Bottle brush hone are NOT  suitable for the modern engines of today and are old technology, and should not be used even as the 1st hone or to try and deglaze a cylinder bore.

Advantages of  Plateau Honing on a Diesel Engine, Gas , Bio Fuel and Petrol cylinder bores.

  • Significantly shorter break-in time;
  • Reduced blow-by for cleaner emissions;
  • Reduced oil consumption in a new engine;
  • Less ring and bore wear for improved engine longevity


Diamond Honing

Diamond is the next technology of honing. It Has all the advantages of plateau honing and more

Diamond honing  lowers the honing costs per cylinder, saves labour, lasts longer (fewer stone changes), and gives better overall bore geometry (straighter and less distortion).

Has a better RA finish , the finer the finish the better the seal,  the better your engine will perform, most high performance engines are Diamond honed

honing cylinder block

Laser honing will Be Next,  or just 3D print yourself another cylinder block !!!

Generator wont start see what the professionals do

  • Battery failure: The obvious causes are a flat battery, dead cells, battery acid builds up on the terminals  , a dirty or bad battery clamp connection, a faulty alternator not charging the battery , fan belt not tight and slipping and can cause an engine squeal noise. may be time for a new battery – check its voltage and do a dead cell test. Do this by removing the covers from each cell and get some one to press the start key . shine a torch into each cell if one bubbles the battery is dead and needs to be replaced
  • If you hear a click click when starting your engine and it wont start or the engine won’t crank over . This could be the starter motor is faulty or the battery or connection is dirty and your not getting enough voltage to your starter motor check the battery failure remedies in this blog. if the battery lead is hot it also could be faulty
  • Ran out of fuel:  Generator fuel tanks are stationary. Unlike a moving vehicle that has if diesel fuel sloshing around its fuel tank. Generator fuel tanks have no movement so this may cause the fuel to become stagnant and may cause the gauges to stick in a position until they break free. So it may say ½ full but it also could be fully empty
  • Controls not in auto:  If the generator has just been tested or serviced check to make sure the main control switch has been left in the off/reset position
  • Low coolant levels:  Look for obvious external water leaks and look for coolant puddles,  a faulty radiator cap letting water escape as it the engine build up pressure , and water escaping out the overflow pipe. If no obvious external water leaks. You may an internal water leak. Check your oil levels. alot of the late model engines a wet liner motors  check out our blog on  Wet Liners
  • Low coolant temp alarms: Low coolant temp alarms will let you know that you have lost all of the coolants or the levels are low, check all the hoses and radiator for leaks. Refer to Low coolant levels
  • High fuel level alarms: The alarm should activate when the fuel tank reaches between 90 and 95 percent capacity. This lets the person fueling the tank know when they should stop filling. There is normally nothing wrong with the generator when this alarm activates. On rare occasions, the external temperature can cause expansion of the fuel will cause the alarm to activate. This will usually occur on an extremely hot summer day
  • Air in the fuel system: Check fuel lines for cracks, check where the fuel line connects to the injector or injector pump for leaks also check inspect fuel filters for fuel leaks as the low pressure and leak will cause the suction of air.Low fuel can also cause the lift pump to suck fuel and air, faulty lift pumps,  cracked diaphragm can pump air into the fuel lines. you will also see a fuel leak from the tell tale hole in some lift pumps.
  • Not sucking fuel : you could have a faulty lift pump, worn lift pump lift arm, worn camshaft journal lift pump lobe. no fuel in fuel tank , blocked fuel filter, your electric fuel pump may have a blown fuse or a bad connection or no longer works.