ABY engine rebuild cost?

[4WheelDrifter]

If the bores have worn badly its going to need a bore and a set of pistons.

Cheaper to get another bottom end in good condition IME.

[aelred]

Bore wear

What the piston/bore tolerance on a I5

Anything over 3 tho. wear I would say it does need new pistons and rebore

[Jonnybravo]

Cheaper to get another bottom end in good condition IME.

Are there that many good ones left ?

I'd of thought with most being high milers that they are all suffering from bore wear to a point.

[4WheelDrifter]

It depends what your goals are.
The original question included the term 'freshen up', and specified no rod upgrades. In most cases a re-hone and a new set of rings with the original block and pistons will do IMHO. Main and big end shells shouldn't have any significant wear, so no need to change them for the sake of it. Oil pump? Is that going to be knackered? Not IME.

So a bore hone, new rings, new valve guides and a full set of gaskets isn't going to cost much on top of the normal service items. Sure you can add a loads more jobs if you want, but are they needed?