Chrysler RAM TRUCK 2500 1994 Service Manual page 865

9 - 144 5.9L (DIESEL) ENGINE •
MIN. 102.0 mm (4.0157 inch)
MAX. 102.116 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.0 76 mm (0.003 inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J 9 2 0 9 - 1 6 7
Fig. 2 Cylinder Bore Diameter
CAMSHAFT BORE DIAMETER
MAX. 54.133 mm (2.1312 inch)
J9109-78
Fig. 3 Camshaft Bores
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.
(3) Cover the lube holes i n the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15° to 25° angles
(Fig. 5). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
MAX.
TAPPET BORE DIAMETER
16.055 mm (0.632 inch)
J9109-79
Fig. 4 Tappet Bore Diameter
TOP OF BLOCK
J9109-124
Fig. 5 Cylinder Bore Crosshatch Pattern
(5) 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.
(6) The
C r o s s h a t c h
angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 6).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 6).
(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. I f 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.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.