Boring Procedure
Important: A 0.5 mm (0.02 in) oversize service piston and a piston
ring set are available for the 5.3 liter engines.
- Measure all pistons with a micrometer to determine the cylinder bore
diameter.
- Before you use any type of boring bar, use a fine file and clean
the top of the cylinder block removing any dirt or burrs. If you do not check
the cylinder block, the boring bar may be improperly positioned, tilted,
and the cylinder bore could be bored at an incorrect angle.
- Carefully follow the instructions furnished by the manufacturer
regarding use of the equipment.
- When you bore the cylinders, make sure all the crankshaft bearing
caps are in place. Tighten the crankshaft bearing caps to the proper torque
in order to avoid distortion of the cylinder bores during final assembly.
- When you take the final cut with a boring bar, leave 0.03 mm
(0.001 in) on the cylinder bore diameter for the finish honing and
fit of the piston.
Honing Procedure
- When honing the cylinders, follow the
manufacturer's recommendations for equipment use, cleaning, and lubrication.
Use only clean, sharp stones of the proper grade for the amount of material
you remove. Dull, dirty stones cut unevenly and generate excessive heat.
Do not hone to final clearance with a coarse or medium-grade stone.
Leave sufficient metal so that all stone marks may be removed with fine-grade
stones. Perform final honing with a fine-grade stone, honing the
cylinder to the proper clearance.
- During the honing operation, thoroughly clean the cylinder bore.
Repeatedly check the cylinder bore for fit with the selected piston.
All measurements of the piston or the cylinder bore should be made with
the components at normal room temperature.
- When honing a cylinder for fit to an oversize piston, first perform
the preliminary honing with a 100 grit stone.
- Perform final cylinder honing with a 240 grit stone and
obtain a 45 degree cross hatch pattern.
A 240 grit
stone is preferred for final honing. If a 240 grit stone is not available,
a 220 grit stone may be used as a substitute.
- When honing to eliminate taper in the cylinder, make full strokes
the complete length of the bore.
Repeatedly check the measurement
at the top, the middle, and the bottom of the bore.
- The finish marks should be clean but not sharp. The finish marks
should also be free from imbedded particles and torn or folded metal.
- By measuring the selected piston at the sizing point and by adding
the average of the clearance specification, you can determine the final cylinder
honing dimension required.
- When finished, the reconditioned cylinder bores should have less
than or meet the specified out-of-round and taper requirements.
- After final honing and before the piston is checked for fit, clean
the cylinder bores with hot water and detergent. Scrub the bores with a stiff
bristle brush and rinse the bores thoroughly with hot water. Do not allow
any abrasive material to remain in the cylinder bores. This abrasive material
may cause premature wear of the new piston rings and the cylinder bores.
Abrasive material will also contaminate the engine oil and may cause premature
wear of the bearings. After washing the cylinder bore, dry the bore with
a clean rag.
- Perform final measurements of the piston and the cylinder bore.
- Permanently mark the top of the piston for the specific cylinder
to which it has been fitted.
- Apply clean engine oil to each cylinder bore in order to prevent
rusting.
Deglazing Procedure
Using a ball type or self centering honing tool, deglaze the cylinder
bore lightly. Deglazing should be done only to remove any deposits that
may have formed. Use a 240 grit stone of silicone carbide or equivalent
material when preforming the deglazing procedure.
A 240 grit stone is preferred for final honing. If a 240 grit
stone is not available, a 220 grit stone may be used as a substitute.