Dodge RAM TRUCK 1500 1995 Service Manual page 1008

B R
i J L (DIESEL) ENGINE I -167
(8) Operate the engine at idle for five to ten min­
utes and check for leaks and loose parts.
CYLINDER BLOCK
REMOVAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the cylinder head from the block.
(3) Remove the camshaft.
(4) Remove the piston/connecting rod assemblies.
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm
(0.0004 inch) in any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0,003 inch).
If the surface exceeds the limit, refer to Cylinder
Block Refacing.
Fig. 1 Combustion Deck Face Measurement
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). If the cylinder
bores exceeds the limit, refer to Cylinder Bore Re­
pair.
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 8). Limit for the
No.l bore applies to the ID of the bushing.
If a bore exceeds the limit, refer to Camshaft Bore
Repair.
Inspect the tappet bores for scoring or excessive
wear (Fig. 4).
If out of limits, replace the cylinder block.
CYLINDER BORES—DE-GLAZE
(1) New piston rings may not seat in glazed cylin­
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing,
(3) Cover the lube holes in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15° to 25° angles
M I N . 102.0 mm (4.0157 inch)
M A X . 102.116 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.0 76 mm (0.003 inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J9209-167
Fig. 2 Cylinder Bore
Diameter
CAMSHAFT BORE DIAMETER
M A X . 54.133 mm (2.1312 inch)
J9109-78
Fig. 3 Camshaft Bores
(Fig. 5). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE SOW engine
oil to de-glaze the bores.
(6) The Crosshatch angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 6).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 6).
(8) Inspect the bore after 10 strokes.