Service manual

• The finish marks should be free from imbedded
particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
5. After the final honing and before the piston is
checked for fit, clean the cylinder bore with hot
water and detergent.
5.1. Scrub the cylinder bores with a stiff
bristle brush.
5.2. Rinse the cylinder bores thoroughly with
clean hot water.
5.3. Dry the cylinder bores with a clean rag.
5.4. Do not allow any abrasive material to
remain in the cylinder bores.
• Abrasive material may cause premature
wear of the new piston rings and the
cylinder bores.
• Abrasive material will contaminate the
engine oil and may cause premature
wear of the bearings.
6. Perform final measurements of the piston and the
cylinder bore.
7. Permanently mark the top of the piston for the
specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in
order to prevent rusting.
Boring Procedure
Caution: Refer to Safety Glasses Caution in
Cautions and Notices.
1. Before starting the honing or reboring operation,
measure all the new pistons with the micrometer
contacting at points exactly 90 degrees from
the piston pin centerline.
2. File the top of the cylinder block in order to
remove any dirt or burrs before using any type of
boring bar.
3. Follow the instructions furnished by the
manufacturer regarding use of the boring
equipment.
4. When reboring the cylinders, make sure all the
crankshaft bearing caps are installed in the
original position and direction.
5. Tighten the crankshaft bearing caps to the proper
torque specifications in order to avoid distortion of
the cylinder bores in the final assembly.
6. When making the final cut with the boring bar,
leave 0.03 mm (0.001 in) on the cylinder bore
diameter for finish honing. This gives the required
position to the cylinder clearance specifications.
Carefully perform the honing and boring operation
in order to maintain the specified clearances
between the pistons, the piston rings, and
the cylinder bores.
Engine Engine Mechanical - 5.0L and 5.7L 6-45
2002 - Unit Repair (May 25, 2001)