- Remove the front oil gallery plugs.
- Remove the rear oil gallery plugs.
- Disconnect the pump oil pressure switch and fitting.
- Clean the following areas:
| • | The engine block in the solvent |
- Inspect the following areas:
| • | The crankshaft bearing webs |
- Measure the following areas:
| • | The cylinder bores for the taper, out-of-round, or the excessive
ring ridge at the top of the ring. |
| • | The cylinder bores for out-of-round |
| • | The cylinder bores for excessive ring ridge at the top of the
ring |
- Recondition the cylinders with less than 0.025 mm (0.0010 in)
of wear or taper with a hone.
Notice: Handle the pistons with care. Do not force the pistons through the cylinder
until you hone the cylinder to the correct size. The piston can be distorted
through careless handling.
- Bore and hone the cylinders with more than 0.025 mm (0.0010 in)
of wear or taper to the smallest oversize piston that will permit complete
resurfacing of all the cylinders. Perform the following procedure in order
to bore and hone the cylinders:
| 8.1. | Draw a flat file across the top of the cylinder head block several
times in order to remove any burrs or gasket materials. |
If the cylinder head block is not completely smooth and flat, tilt the
boring bar in order to produce an incorrect angle of the cylinder to the crankshaft.
| 8.2. | Measure the piston 11.5 mm (0.45 in) from the bottom
of the piston skirt and at right angles to the piston pin in order to install
the piston correctly. |
| 8.3. | Bore the cylinder to the same diameter as the piston. |
| 8.4. | Hone the cylinder in order to provide the specified clearance.
Follow the manufacturer instructions of the proper boring equipment to use. |
| 8.5. | During the honing operation occasionally: |
| 8.5.1. | Clean the cylinder bore. |
| 8.5.2. | Measure the cylinder bore for a proper piston fit. |
| 8.6. | Finish the honing operation with a 45 65 degrees
cross-hatch pattern on the cylinder walls. The finish marks should be clean
but not sharp, free from imbedded particles and torn or faded metal. |
| 8.7. | Place a permanent mark on each piston to match it to its proper
cylinder. |
| 8.8. | Use a stiff bristle brush, hot water, and detergent in order to
clean the cylinder bores and the block. |
| • | Abrasive materials left in the cylinder bores will cause rapid
wear of the piston rings, bearings, and other engine assembly parts. |
| • | Do not use kerosene or gasoline for the cleaning. |
| 8.9. | Swab cylinder bores with a light engine oil and a clean cloth.
Wipe the cylinder bores out with a clean dry cloth. |
