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I've decided to rebuild the tired old G13A out of my '87 Samurai. Yes, I have considered swaps, but I have my reasons for keeping the original motor. The head gasket blew and the rings on cylinder one were pretty much gone. I will be boring out this block, among other things. My question is, how does one go about boring a sleeved engine, and how much can this block be safely bored out? I've already spoken with one machine shop and I didn't really like what the guy was telling me--I've always been told that sleeved engines cannot just be bored, they HAVE to be re-sleeved. This guy told me he would just bore the sleeves, is this safe? Also, I've seen a few different options as far as pistons go (as much as 0.040" over). Of course I want to go with the biggest bore possible to get more power out of this motor. I asked the machine shop guy how much he could SAFELY bore this block without weakening it. He said, "As long as you can find pistons, I can bore it." I didn't like that answer, the man is used to building muscle car engines. So anyway, I'm just looking for a 2nd, 3rd, 4th, or maybe even 5th opinion. I've only got one block, and I don't feel like trying to find another one if some knuckle-head machine shop screws it up. Any advice would be greatly appreciated...
 

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I've decided to rebuild the tired old G13A out of my '87 Samurai. Yes, I have considered swaps, but I have my reasons for keeping the original motor. The head gasket blew and the rings on cylinder one were pretty much gone. I will be boring out this block, among other things. My question is, how does one go about boring a sleeved engine, and how much can this block be safely bored out? I've already spoken with one machine shop and I didn't really like what the guy was telling me--I've always been told that sleeved engines cannot just be bored, they HAVE to be re-sleeved. This guy told me he would just bore the sleeves, is this safe? Also, I've seen a few different options as far as pistons go (as much as 0.040" over). Of course I want to go with the biggest bore possible to get more power out of this motor. I asked the machine shop guy how much he could SAFELY bore this block without weakening it. He said, "As long as you can find pistons, I can bore it." I didn't like that answer, the man is used to building muscle car engines. So anyway, I'm just looking for a 2nd, 3rd, 4th, or maybe even 5th opinion. I've only got one block, and I don't feel like trying to find another one if some knuckle-head machine shop screws it up. Any advice would be greatly appreciated...
When we did the engine in the Stalker Project, I went 0.020 over and then stuffed it with all new parts from JFE. The block has not given me any problems at all.

JFE Power - iZook
 

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Hi , You Really Need to Measure the Bock to decide The Bore, I have had sleeved engines Bored, that is Not a Problem, IF you don't go to Big ! also are your Pistons stock Bore ? If they are, and your Bock measurements are good , I would feel good going to .030, Maybe .040 ? what pistons are avail ?? Your Over all Mileage on engine ? So pistons avail and Block Measurements are what you Should go by.. ..(note that this all Involves alot of Cash !)
If bore isnt to Bad ? You can Hone Your Cyls and Go for Cheaper..
 

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When getting our the kit from JFE, we first took the bare block to the machine shop and had the journals and cylinders 'miced to see how far we had to go with the bore. Even if you have (what you think is) a stock motor, you can't rely on what the previous owner told you... Trust can get expensive.
When the machinest told us how far he would have to go to make it right, we passed the info on to John (JFE) and he sent the right kit. You can go up to 0.040 on a zook motor and still be safe.
 

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Discussion Starter #5
The engine has around 150,000 miles on it with stock bore and pistons. Thank you so much for the advice so far guys!
 

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Which engine do you have? The Samurai came with both a 1298 and a 1324.
 
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