Dodge 2001 Ram 1500 Owner's Manual page 1413

9 - 266 ENGINE 5.9L DIESEL
ENGINE BLOCK (Continued)
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.
Fig. 74 Block Bore for Repair Sleeve Dimensions
1 - BORE DIAMETER
2 - STEP DIMENSION
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER
104.500 + 0.015 mm
(4.1142 + 0.0006 in.)
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 it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 75).
A sleeve driver can be constructed as follows (Fig. 76).
STEP DIAMETER
6.35 mm (0.25 in.)
Fig. 75 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
Fig. 76 Sleeve Driver Construction
1 - DRIVE
2 - HANDLE
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM
A
B
C
D
E
F
BR/BE
MEASUREMENT
127 mm (5 in.)
38 mm (1.5 in.)
6.35 mm (0.25 in.)
25.4 mm (1 in.)
101 mm (3.976 in.)
107.343 mm (4.226 in.)