Dodge RAM 1500 1998 Owner's Manual page 1488

DR
ENGINE BLOCK (Continued)
(6) Use a drill, a fine grit Flex-hone and a mixture
of equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.
(7) The crosshatch angle is a function of drill
speed and how fast the hone is moved vertically (Fig.
47).
(8) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 47).
Fig. 47 De-Glazing Drill Speed and Vertical Speed
(9) Inspect the bore after 10 strokes.
(10) Use a strong solution of hot water and laun-
dry detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.
(11) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(12) 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. Place a clean shop towel around the top main
bearing saddle to deflect water and residue from pis-
ton cooling nozzels. Remove directed piston cooling
nozzles if installed.
(13) Be sure to remove the tape covering the lube
holes, rod journals, and piston cooling nozzles 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:
ENGINE 5.9L DIESEL
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. 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.
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 30°