Dodge ram truck 3500 1996 Service Manual page 1161

B R 1.91 (DIESEL) ENGINE 9 - 171
S E R V I C E P R O C E D U R E S ( C o n t i n u e d )
1st REFACE 0.15 mm
(0.0058 inch)
2nd REFACE
0.35 mm
(0.0138 inch)
®
Total
0.50 mm
(0.0197 inch)
® Standard
323.00 m m ±0.10 mm
(12.7165 inch ±0.0039 inch)
1st REFACE
322.85 m m ±0.10 m m
(12.7106 inch ±0.0039 inch)
2nd REFACE
322.50 m m ±0.10 mm
(12.6968 inch ±0.0039 inch)
J9109-118
Fig. 15 Refacing Dimensions of the Cylinder Block
1st REFACE X
2nd REFACE XX
J9109-116
Fig. 16 Stamp Block after Reface
CYLINDER
B O R E
REPAll
Cylinder bore(s) can be repaired by one of two
methods:
• Method 1:—Over boring and using oversize pis­
tons 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. 17). 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. 17).
BORING AND
HONING DIAMETERS
BORING DIAMETER DIMENSION
1st REBORE - 102.469 m m
(4.0342 inch)
2nd REBORE - 102.969 m m
(4.0539 inch)
HONING DIAMETER DIMENSIONS
STANDARD 102.020 ± 0.020 m m
(4.0165 ±0.0008 inch)
1st REBORE 102.520 ± 0.020 m m
(4.0362 ± 0.0008 inch)
2nd REBORE 103.020 ± 0.020 mm
(4.0559 ± 0.0008 inch)
CHAMFER DIMENSIONS
Approx. 1.25 m m (0.049 inch)
by 15°
J9109-119
Fig. 17 Cylinder Bore Dimensions