Cylinder Block: Service

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The most desired 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.

Remove the gallery plugs.
1. Remove the tappet oil gallery plugs.
2. Remove the main oil gallery plug.
Fig 1: Removing Gallery Plugs
Courtesy of FORD MOTOR CO.

NOTE: A sealing compound must be applied to the gallery plugs prior to installation.

Apply a coating of Pipe Sealant with Teflon® XW7Z-19554-AA or equivalent meeting Ford specification WSK-M2G350-A2.
Spray cylinder wall using Rust Penetrant and Inhibitor XL-1 or equivalent meeting Ford specification and ESR-M99C56-A.

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 can cause 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 performed.

NOTE: A 4-inch 120 grit rating "flexhone" is required to hone the cylinders of this diesel engine.

Fig 2: Honing Cylinder

Courtesy of FORD MOTOR CO.

Insert the hone into a cylinder and begin honing for three seconds at a cycle of two strokes per second. Remove the hone from the cylinder.
Wipe a section of the cylinder wall and inspect the crosshatch pattern comparing it to the neighboring (untouched) cylinder.

Fig 3: Inspecting Crosshatch Pattern
Courtesy of FORD MOTOR CO.

CAUTION: Continuously spray the cylinder wall with Rust Penetrant and Inhibitor XL-1 or equivalent meeting Ford specification ESR-M99C56-A while honing. Do not exceed more than 25 strokes per cylinder bore because too much metal could be removed from the cylinder wall.

Repeat the honing process until the cylinder wall has a satin-like finish, or the maximum 25 strokes are achieved.

CAUTION: If the following step is not followed, rusting of the cylinder bore(s) can occur.

Clean and preserve the cylinder bores.
1. Clean the cylinder bores using a mild soap and water.
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.