Dodge dakota 2002 Service Manual page 1563

9 - 314 ENGINE 5.9L DIESEL
ENGINE BLOCK (Continued)
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. 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.
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. 48). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
Fig. 48 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.
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°
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. 49).
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. 49 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.
DR
STEP DIMENSION
6.35 mm (0.25 in.)