Chrysler RAM TRUCK 2500 1994 Service Manual page 850

5JL (DIESEL) ENGINE 9 - 129
J 9 1 0 9 - 3 6
Fig. 5 Cylinder Head Bolt Removal Sequence-
Cylinder Head Hot
MIN.
102.0
mm
(4.0157
inch)
MAX.
102.116
mm
(4.0203
inch)
Out-of-Round
0.038
mm
(0.0015
inch)
Taper
0.76
mm
(0.003
inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J9109-75
Fig. 6 Cylinder Bore Diameter
Check the head distortion (Fig. 7). The distortion of
the combustion deck face is not to exceed 0.010 mm
(0.0004 inch) in any 50.8 mm (2.00 inch) diameter.
Overall variation end to end or side to side 0.30 mm
(0.012 inch).
D O NOT proceed with the in-chassis overhaul if
the cylinder head or block surface is damaged or not
flat (within specifications).
REFACING HEAD SURFACE
The cylinder head combustion deck may be refaced
in whatever increments necessary to clean up the
surface and maintain the surface finish and flatness
tolerances. The combined total of stock removed must
not exceed 1.00 mm (0.03937 inch). The amount of
stock removed each time must be steel stamped
above combustion deck edge, on the lower right hand
Fig. 7 Cylinder Head Combustion Deck Face
Measurement
corner of the rear face (Fig. 8). Check valve protru­
sion after head surface refacing.
Surface finish requirements are 1.5-3.2 microme­
ters (60-126 microinch).
REFERENCE
STOCK TOTAL (MAX.)
1.00 mm (0.03937 inch)
REFERENCE HEIGHT (MIN.)
94.00 ±0.25 mm
(3.7008 ±0.0010 inch)
SURFACE FINISH
1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-134
Fig. 8 Cylinder Head Stock Removal
CLEANING
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head in hot soapy water solution
(88°C or 140°F).
After rinsing, use compressed air to dry the cylin­
der head.
Polish the gasket surface with 400 grid paper. Use
an orbital sander or sanding block to maintain a flat
surface.
INSTALLATION
(1) The cylinder block and head must be clean and
dry.