Dodge ram truck 3500 1996 Service Manual page 1163

5.9L (DIESEL) ENGINE 9 - 173
6EHWIC3B
P R O C E D U R E S
fContinuedf
A sleeve driver can be constructed as follows (Fig.
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 mm (3.976 inch)
F = 107.343 mm (4.226 inch)
J9109-122
Fig. 21 Sleeve Driver Construction
Set up a boring bar and machine the sleeve to
101.958 mm (4.014 inch) - (Fig. 22).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s) - (Fig.
22).
SLEEVE DIAMETER - 101.956 mm
(4.014 inch)
SLEEVE PROTRUSION
M I N . - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (0,049 inch)
BY 15° *
J9109-123
Fig. 22 Sleeve Machining Dimensions
A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch).
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 with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound i f the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
CAM BORE REPAIR
The front cam bushing bore can be bored to 57.740
Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate
and rear cam bores may be bored to 57.240 mm
±0.018 mm (2.253 inch ±0.0007 inch) oversize.
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. I t is
not necessary to repair undamaged cam bores i n
order to repair individually damaged cam bores. The
standard front bushing cannot be used to repair
intermediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a
3.2 mm (0.125 inch) rod to pass through freely (Fig.
23).
Fig. 23 Oil Hole Alignment