Dodge 2001 Ram 1500 Owner's Manual page 1412

BR/BE
ENGINE BLOCK (Continued)
(11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If 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.
STANDARD PROCEDURE—CYLINDER BORE
REPAIR
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
Cylinder bore(s) can be repaired by one of two
methods:
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. 72). 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. 72).
Fig. 72 Cylinder Bore Dimensions
1 - CHAMFER
ENGINE 5.9L DIESEL
CYLINDER BORE DIMENSION CHART
DESCRIPTION
BORING DIAMETER
DIMENSION
HONING DIAMETER
DIMENSIONS
CHAMFER
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 (Fig. 73). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
Fig. 73 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. 74).
9 - 265
MEASUREMENT
1st. REBORE - 102.469
mm (4.0342 in.)
2nd. REBORE - 102.969
mm (4.0539 in.)
STANDARD - 102.020 ±
0.020 mm (4.0165 ±
0.0008 in.)
1st. REBORE - 102.520
± 0.020 mm (4.0362 ±
0.0008 in.)
2nd. REBORE - 103.020
± 0.020 mm 4.0559 ±
0.0008 in.)
Approx. 1.25 mm (0.049
in.) by 15°