Dodge ram truck 3500 1996 Service Manual page 1160

9 - 170 5.9L (DIESEL) ENGINE
B R
SERVICE PROCEDURES (Continued)
Measure the valve seat width indicated by the
lapped surface (Fig. 12). The width limits are 1.5-2.0
mm (0.060-0.080 inch). I f required, grind lower area
with 60° stone and upper area with 15° stone (Fig.
12). Be sure to center the seat on the valve face.
Maintain the valve seat within limits.
MAXIMUM
J9109-45
Fig, 12 Waive Seat Width
SEiWiCE VALWE SEAT REPLACEMENT
To replace service seat inserts, machine the insert
in the same manner as i f machining out the internal
seat. Hold the same tolerances and follow the same
installation procedures.
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
(Fig. 13). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
TOP OF BLOCK
Fig. 13 Cylinder Bore Crosshatch Pattern
(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.
14).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 14).
1 STROKE ( f + | ) / P E R S E C O N D
Fig. 14 De-Glazing Drill Speed and Wertical Speed
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. I f grit residue is
still present, repeat the cleaning process until all res­
idue is removed. Wash the bores - and the complete
block assembly with solvent and dry with compressed
air.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.
CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). I f addi­
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 15).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 16).
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.