- Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
- Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
- Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
- Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
- Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.
Contents
Wiring diagrams Section: Mechanical- Fastener Tightening Specifications
- Engine Mechanical Specifications
- Sealers, Adhesives, and Lubricants
- Diagnostic Starting Point - Engine Mechanical
- Strategy Based Diagnostics
- Visual/physical Inspection
- Intermittent
- Symptom List
- Base Engine Misfire Without Internal Engine Noises
- Base Engine Misfire with Abnormal Internal Lower Engine Noises
- Base Engine Misfire with Abnormal Valve Train Noise
- Base Engine Misfire with Coolant Consumption
- Base Engine Misfire with Excessive Oil Consumption
- Engine Noise on Start-Up, but Only Lasting a Few Seconds
- Upper Engine Noise, Regardless of Engine Speed
- Lower Engine Noise, Regardless of Engine Speed
- Engine Noise Under Load
- Engine Will Not Crank - Crankshaft Will Not Rotate
- Coolant in Combustion Chamber
- Coolant in Engine Oil
- Engine Compression Test
- Tools Required
- Oil Consumption Diagnosis
- Low or No Oil Pressure
- Locating and Identifying the Leak
- Visual Inspection Method
- Powder Method
- Black Light and Dye Method
- Possible Causes for Leaks
- Crankcase Ventilation (Cv) System Inspection
- Results of Incorrect Operation
- Diagnostic Aids
- Test Description
- Drive Belt Whine Diagnosis
- Drive Belt Tensioner Diagnosis
- Removal Procedure
- Installation Procedure
- Engine Mount Inspection
- Valve Stem Oil Seal and Valve Spring Replacement
- Crankshaft Balancer Replacement
- Draining Fluids and Oil Filter Removal
- Crankshaft Balancer Removal
- Engine Flywheel Removal
- Drive Belt Tensioner Removal
- Engine Mount Support and Strut Bracket Removal
- Engine Lift Bracket and Generator Bracket Removal
- Engine Lift Bracket Removal - Rear
- Oil Level Indicator and Tube Removal
- Oil Filter Adapter Removal
- Exhaust Crossover Pipe Removal
- Exhaust Manifold Removal - Left
- Exhaust Manifold Removal - Right
- Water Outlet and Thermostat Removal
- Valve Rocker Arm Cover Removal - Left
- Valve Rocker Arm Cover Removal - Right
- Intake Manifold Removal - Upper
- Intake Manifold Removal - Lower
- Valve Rocker Arm and Push Rod Removal
- Valve Lifter Removal
- Water Pump Removal
- Cylinder Head Removal - Left
- Cylinder Head Removal - Right
- Oil Pan Removal
- Oil Pump Removal
- Oil Pump Drive Removal
- Engine Front Cover Removal
- Timing Chain and Sprockets Removal
- Camshaft Removal
- Piston, Connecting Rod, and Bearing Removal
- Crankshaft Rear Oil Seal Removal
- Crankshaft and Bearings Removal
- Engine Block Disassemble
- Engine Block Cleaning and Inspection
- Boring Procedure
- Honing Procedure
- Engine Block Assemble
- Crankshaft and Bearings Cleaning and Inspection
- Bearing Selection
- Crankshaft Balancer Cleaning and Inspection
- Engine Flywheel Cleaning and Inspection
- Timing Chain and Sprockets Cleaning and Inspection
- Valve Lifters Cleaning and Inspection
- Valve Rocker Arm and Push Rods Cleaning and Inspection
- Cylinder Head Cleaning and Inspection
- Oil Pump Disassemble
- Oil Pump Cleaning and Inspection
- Engine Front Cover Cleaning and Inspection
- Valve Rocker Arm Cover Cleaning and Inspection
- Oil Pan Cleaning and Inspection
- Intake Manifold Cleaning and Inspection - Lower
- Intake Manifold Cleaning and Inspection - Upper
- Exhaust Manifold Cleaning and Inspection
- Water Pump Cleaning and Inspection
- Thread Repair
- Service Prior to Assembly
- Piston, Connecting Rod, and Bearing Installation
- Camshaft Installation
- Timing Chain and Sprockets Installation
- Engine Front Cover Installation
- Oil Pump Drive Installation
- Oil Pump Installation
- Oil Pan Installation
- Water Pump Installation
- Valve Lifter Installation
- Valve Rocker Arm and Push Rod Installation
- Intake Manifold Installation - Lower
- Intake Manifold Installation - Upper
- Valve Rocker Arm Cover Installation - Right
- Valve Rocker Arm Cover Installation - Left
- Water Outlet and Thermostat Installation
- Exhaust Manifold Installation - Left
- Exhaust Manifold Installation - Right
- Exhaust Crossover Pipe Installation
- Oil Filter Adapter Installation
- Oil Level Indicator and Tube Installation
- Engine Lift Bracket and Generator Bracket Installation
- Engine Mount Support and Strut Bracket Installation
- Engine Lift Bracket Installation - Rear
- Drive Belt Tensioner Installation
- Engine Flywheel Installation
- Crankshaft Balancer Installation
- Functional Check of PCV Valve
- Drive Belt System Description
- Engine Component Description
- Lubrication Description
- Cleanliness and Care
- Separating Parts
- Replacing Engine Gaskets
- Use of Room Temperature Vulcanizing (Rtv) and Anaerobic Sealer
- Applying Rtv Sealer
- Applying Anaerobic Sealer
- Tools and Equipment
- Special Tools
- Abbreviations
- Airbag
- Anti-Lock/traction Control
- Automatic HVAC System
- Automatic Trans
- Axle Shafts
- Basic Trouble Shooting
- Body Electrical
- Brakes
- Cabin Air Filter
- Charging System
- Check Lists
- Communication Devices
- Cooling System (Mechanical)
- Cruise Control Systems
- Diagnostic Connector Locations
- Differentials & Drive Axles
- Door Locks & Anti-Theft Systems
- Drive Cycles
- Driveline/axles
- Driveshaft & Universal Joints
- DTC Index
- Electrical
- Electrical Component Locations
- Emission Applications
- Engine
- Engine Performance
- Entertainment Systems
- Exhaust
- Exterior Body Panels
- Exterior Lights
- Exterior/interior Trim
- Frames, Subframes & Crossmembers
- Fuses & Circuit Breakers
- Gauges & Instrument Panels
- Heated Glass/defoggers
- Hoist/jack
- Horns
- Identification
- Ignition Switch/steering Lock
- Lubrication System
- Manual & Power Steering
- Manual HVAC System
- MAP Guidelines
- Mechanical
- Mechanical - Hydraulic
- Memory Modules
- Metric Conversions
- Mode 6
- Oem General Information
- Paint/coatings
- Parking Brake System
- Reset Procedures
- Restraints Control Systems
- Seats
- Specifications
- Steering
- Sun Roof/t-Top/convertible Top
- Suspension Front
- Suspension Rear
- Testing & Diagnostics
- Traction Control Disable
- Transfer Case
- Transmission
- Wheel & Tire System
- Wheel Alignment
- Wiper/washer Systems