Dodge ram truck 3500 1996 Service Manual page 1162

9 - 172 5.91 (DIESEL) ENGINE
BR
SERVICE PROCEDURES
(Continued)
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. 18). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
TOP O F BLOCK
Fig. 18 Crosshatch Pattern of Repaired Sleeve(s)
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.
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. 19).
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.
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 i t
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
BLOCK REBORE FOR REPAIR SLEEVE
BORE DIA. - 104.500 +0.015 mm
(4.1142 +0.0006 inch)
STEP DIM. - 6.35 mm (0.25 inch)
J9109-120
Fig. 19 Block Bore for Repair Sleeve Dimensions
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until i t contacts the step at the bottom of the bore
(Fig.
20).
J9109-121
Fig. 20 Sleeve Installation