Dodge dakota 2002 Service Manual page 1564

DR
ENGINE BLOCK (Continued)
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 50).
Fig. 50 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
A sleeve driver can be constructed as follows (Fig.
51).
Fig. 51 Sleeve Driver Construction
1 - DRIVE
2 - HANDLE
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM
A
B
C
D
E
F
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.)
ENGINE 5.9L DIESEL
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM
SLEEVE PROTRUSION
SLEEVE DIAMETER
SLEEVE CHAMFER
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 if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDURE—CAM BORE REPAIR
For standard bushings, not oversized, maximum
front and rear cam bushing bore diameter is 59.248
mm. (2.3326 in.). DO NOT bore the intermediate cam
bore to the front cam bore oversize dimensions. Max-
imum front and rear camshaft bushing installed
diameter is 54.147 mm. (2.1318 in.). Minimum
installed diameter is 54.083 mm. (2.1293 in.). Maxi-
mum intermediate camshaft bore diameter is 54.164
mm. (2.1324 in.).
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. It is
not necessary to repair undamaged cam bores in
order to repair individually damaged cam bores. The
9 - 315
MEASUREMENT
MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
101.956 mm (4.014 in.)
APPROX. 1.25 mm
(0.049 in.) by 15°