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Cylinder Bore Honing: Service

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. The most preferred cylinder block cleaning method is the "hot tank" method. All gallery plugs must be removed prior to hot tanking the cylinder block. If a hot tank is not available, soap and water is the approved alternative cleaning method.
  2. Remove the gallery plugs.
    1. Remove the tappet oil gallery plugs.
    2. Remove the main oil gallery plug.
    3. NOTE: A sealing compound must be applied to the gallery plugs prior to installation.
  3. Apply a coating of Threadlock 262 to the gallery plugs and install.
    4. CAUTION: Continuously spray the cylinder wall with Penetrating and Lock Lubricant while honing. Do not exceed more than 25 strokes per cylinder bore because too much could be removed from the cylinder wall.
  4. Spray the cylinder wall using Penetrating and Lock Lubricant.
    5. Fig 1: Honing The Cylinders
    GF0005662Courtesy of FORD MOTOR CO.
    CAUTION: Remove the piston cooling oil jets prior to honing the cylinders. Failure to do so will cause damage to the piston cooling oil jets.
    CAUTION: Always remove the hone from the cylinders while the hone is still rotating. Failure to do so may cause an inconsistent pattern to form allowing excess engine oil to enter the combustion chamber.
    NOTE: It is not necessary to remove the crankshaft to hone the cylinder block. However, it is recommended to oil the crankshaft journals then wrap them with clean shop towels and tape.
    NOTE: An air or electric drill motor with an adjustable speed down to 100 RPM is required to hone the cylinders. If a drill motor meeting this requirement is not available, cylinder honing cannot be carried out.
    NOTE: A 101.6 mm (4 in) deglazing hone is required to hone the cylinders of this diesel engine.
  5. Insert the hone into a cylinder and begin honing for 3 seconds at a cycle of 2 strokes per second. Remove the hone from the cylinder.
    6. Fig 2: Cylinder Wall Crosshatch Pattern
    GF0005663Courtesy of FORD MOTOR CO.
  6. Wipe a section of the cylinder wall and inspect the crosshatch pattern, comparing it to the neighboring (untouched) cylinder.
    7. CAUTION: Continuously spray the cylinder wall with Penetrating and Lock Lubricant while honing. Do not exceed more than 25 strokes per cylinder bore because too much could be removed from the cylinder wall.
  7. Repeat the honing process until the cylinder wall has a satin-like finish, or the maximum 25 strokes are achieved.
    8. CAUTION: If the following steps are not followed, rusting of the cylinder bore(s) can occur.
  8. Clean and preserve the cylinder bores.
    1. Clean the cylinder bores using a mild soap and water solution.
    2. Dry the cylinder bores thoroughly using a clean, lint-free cloth.
    3. Soak a clean cloth in clean engine oil, and wipe the cylinder bores with the cloth.
    4. Drape a clean cloth over the cylinder block to keep contaminants out of the cylinder bores.
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