Dodge RAM TRUCK 1500 1995 Service Manual page 1011

9 - 170 5.9L (DIESEL) ENGINE
B R
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl­
inder bore beyond the oversize limit.
B L O C K REBORE F O R R E P A I R
SLEEVE
BORE DIA. - 104.500 + 0.015 mm
(4.1142 +0.0006 Inch)
STEP DIM. - 6.35 mm (0.25 inch)
J9109-120
Fig. 11 Block Bore for Repair Sleeve Dimensions
After machining - the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
(10°F)
or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 12).
Fig. 12 Sleeve Installation
A sleeve driver can be constructed as follows (Fig.
DRIVE - ALUMINUM
HANDLE - STEEL
A = 127 mm (5 inch)
B = 38 mm (1.5 inch)
C = 6.35 mm (0.25 inch)
D = 25.4 mm (1 inch)
E - 101 m m (3.976 inch)
F = 107.343 mm (4.226 inch)
J9109-122
Fig. 13 Sleeve Driver Construction
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch) - (Pig. 14).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s) - (Fig.
14).
SLEEVE DIAMETER - 101.956 mm
(4.014 inch)
SLEEVE PROTRUSION
MIN. - FLUSH WITH BLOCK
MAX. - 0.050 m m (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 m m (Q.Q49 inch)
BY 15° •
' J9109-123
Fig. 14 Sleeve Machining Dimensions
A correctly honed surface w i l l h a v e a Crosshatch
appearance
with the lines at
15°
to
25°
angles with