Dodge ram truck 3500 1996 Service Manual page 996

SERVICE PROCEDURES
( C o n t i n u e d )
• Installing an Insert Into the tapped hole to bring
the hole back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, Is the best tool for
this job. In addition to deglazing, it will reduce taper
and out-of-round, as well as removing light scuffing,
scoring and scratches. Usually, a few strokes will clean
up a bore and maintain the required limits.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done i f
the cylinder bore is straight and round. Use a cylin­
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf­
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a Crosshatch pattern.
The hone marks should INTERSECT at 50° to 60°
for proper seating of rings (Fig. 8).
CROSSHATCH s
Fig. 8 Cylinder Bore Crosshatch Pattern
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper Crosshatch
angle. The number of up and down strokes per minute
can be regulated to get the desired 50° to 60° angle.
Faster up and down strokes increase the Crosshatch
angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter­
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure.
Refer to Group 14, Fuel System.
(2) Disconnect the negative cable from the battery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs or
fuel injectors (diesel engine) to catch any fluid that
may possibly be under pressure in the cylinder head.
Remove the spark plugs or fuel injectors (diesel
engine).
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs and injectors (diesel
engine) removed, rotate the crankshaft using a
breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
( 7 ) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
( 9 ) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs or fuel injectors (die­
sel engine). Tighten the spark plugs to 41 N-m (30 ft.
lbs.) torque. Tighten the fuel injector nuts to 60 N-m
(44 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N-m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. Refer to Group 0, Lubrica­
tion and Maintenance.
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.