For 1990-2009 cars

1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. Refer to Thread Repair in Engine Mechanical.
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if warpage exceeds 0.05 mm (0.0020 in).
9. Inspect the crankcase rails for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Use the J 8087 to inspect the cylinder bores. Inspect for the following items:

• | Wear

• | Taper

• | Runout

• | Ridging

Important: If the bore is worn beyond the limits, refit the bore with oversized pistons. Select the smallest available oversize piston.

11. Leave sufficient material to allow honing when fitting the piston.