Block and Piston Inspection

Block and Piston Inspection

1. Remove the crankshaft and the pistons. Crankshaft and Piston Removal

2. Check the piston for distortion or cracks.

3. Measure the piston skirt diameter at a point 16 mm (0.6 in.) ('00-03 models), or 10 mm (0.4 in.) ('04-09 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, the bolts, and the bolt holes.

5. Clean the lower block mating surfaces.

6. Put the lower block on the engine block.






7. Apply new engine oil to the threads of the bearing cap bolts. Tighten the bearing cap bolts in sequence to 29 N-m (3.0 kgf-m, 22 lbf-ft).






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.






11. Check the top of the engine 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 the engine block for excessive wear.