Dodge RAM TRUCK 1500 1995 Service Manual page 1010

5.9L (DIESEL) ENGINE .9-169
Fig. 8 Stamp Block after Reface
• Method 1:—Over boring and using oversize pistons
and rings.
• Method 2:—Boring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm- (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 9). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 9).
A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 10). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maximum of 1.2 micrometer (48 microinch) sur­
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white,
lint-free, lightly-oiled cloth. There should be no grit
residue present.
If the block is not to be used right away, coat it
with a rust-preventing compound.
BORING AND
HONING DIAMETERS
BORING DIAMETER DIMENSION
1st REBORE - 102,469 mm
(4.0342 inch)
2nd REBORE - 102.969 mm
(4.0539 inch)
HONING DIAMETER DIMENSIONS
STANDARD 102.020 ±0.020 mm
(4.0165 ±0.0008 inch)
1st REBORE 102.520 ± 0.020 mm
(4.0362 ± 0.0008 inch)
2nd REBORE 103.020 ± 0.020 mm
(4.0559 ± 0.0008 inch)
CHAMFER DIMENSIONS
Approx. 1.25 mm (0.049 inch)
by 15°
J9109-119
6 x 3.5 Fig. 9 Cylinder Bore Dimensions
TOP OF BLOCK
Fig. 10 Crosshatch Pattern of Repaired Sleeve(s)
METHOD 2—REPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 11).