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Alternative Repair Procedures
PageiK-6
Base Engine Components
DODGE Turbo Diesel
Cylinder Bore(s)
Block cylinder bores may be rebored twice before use of a
repair sleeve is required. The first rebore is 0.50mm [0.197
inch] oversize. The second rebore is 1.00mm[0,0393 inch]
oversize.
Boring Diameter Dimensions
A =
102.469mm [4.0342 inch]
102.969mm [4.0539 inch]
Honing Diameter Dimensions
First rebore
Second rebore
B »
102.020 ± .020mm
Standard bore
[4.0165 ±.0008 inch]
102.520 ± .020mm
First rebore
[4.0362 ±.008 Inch]
103.020 ± .020mm
Second rebore
[4.0559 ±.0008 inch]
After boring to size, use a honing stone to chamfer the edge of the
bore to Dimension C.
Approximately 1.25mm
[.049 inch] X 15 Degrees
A correctly honed surface will have a cross-hatch appearance
wm/
with the lines at 15 to 25 degree angles with the top of the
5 n cylinder block.
Rough hone: Use 80 grit honing stones.
Finish hone: Use 280 grit honing stones.
A maximum of 1.2 micrometer [48 microinch] surface finish
must be obtained.
V I
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.
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