Block and Piston Inspection
Block and Piston Inspection1. Remove the crankshaft and pistons.
2. Check the piston for distortion or cracks.
3. Measure the piston diameter at a point 16 mm (0.6 inch) (2000-2003 models), or 10 mm (0.4 inch) (2004-2006 models) from the bottom of the skirt. There are two standard-size pistons (No Letter or A, and B). The letter is stamped on the top of the piston. Letters are also stamped on the engine block as cylinder bore sizes.
4. Remove all of the old liquid gasket from the lower block mating surfaces, bolts, and bolt holes.
5. Clean the lower block mating surfaces.
6. Put the lower block on the engine block.
7. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf-m, 22 ft. lbs.).
8. Tighten the bearing cap bolts an additional 60°.
9. Measure the wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the block is to be rebored, refer to step 12 after reboring.
10. Scored or scratched cylinder bores must be honed.
Precision Straight Head
11. Check the top of the block for warpage. Measure along the edges and across the center as shown.
12. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and engine block for excessive wear.