Dodge D250 1990 Service Manual page 340

Base Engine Components
DODGE Turbo Diesel
Alternative Repair Procedures
Page9K-9
Driver Construction
Driver - aluminum
Handle -steel
A = 127mm [5 inch]
B « 38mm [1.5 inch]
C = 6.35mm [0.250 inch]
D = 25.4mm [1.00 inch]
E - 101mm [3.976 Inch]
F - 107.343mm [4.226 Inch]
Set up a boring bar and machine to the following dimensions.
A = 101.956mm [4.014 inch]
B = Minimum - flush with block
Maximum - .05.mm [.0019 inch] protrusion
After removing the boring bar
f
use a honing stone to chamfer
the comer of the repair sleeve(s) to dimension C.
C = Approximately 1.25mm [.049 inch] X15 Degrees
A correctly honed surface will have a cross-hatch appearance f < ^
with the lines at 15 to 25 degree angles with the top of the
cylinder block.
- Rough hone: use 80 grit honing stones.
- Finish hone: use 280 grit honing stones.
Finished bore inside dimension: 102.020 ± .020mm 4.0165 -t
.0008 inch]
A maximum of 1.2 micrometer [48 microinch] surface 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.