This story has a happy ending, which it should this close to Christmas. First some details. In late August I noticed my oil pressure had started to drop. A check showed that the bearings had seen better days and since I was going to rebuild the engine I figured why not go up to 87mm pistons and liners. I posted a message on this board asking for peoples experieneces with replacement piston and liner sets. After a number of responses I went for the Mahle 87mmm set. Here's where it gets interesting. I had my block cleaned and machined by a reputible shop here in NorCal. When I went to put in the new liners they wouldn't fit. Measuring both the new and old liners showed a difference of .004 to .005. I spoke to a number of people and all said, they should just drop in and don't force them into the block. I checked with Moss, British Parts Northwest, and TRF and all of their liners were the same diameter as the Mahle liners I had. I should add that all three were very helpful in assisting me with my problem. After much frustration, a friend and I used emory cloth on the lower end of the Mahle liners. After taking off about .002 they fit, very nicely. So if anyone is installing a new set of pistons and liners and having trouble making them fit maybe what I went through can help. Merry Christmas and Happy Holidays!
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