Dodge RAM 1500 1998 Owner's Manual page 1489

9 - 266 ENGINE 5.9L DIESEL
ENGINE BLOCK (Continued)
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. 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.
STEP DIMENSION
6.35 mm (0.25 in.)
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. 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
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch).
DR
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.)