Chrysler RAM TRUCK 2500 1994 Service Manual page 866

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5.9L (DIESEL) ENGINE 9 - 145
1 STROKE (f+|)/PER SECOND
Fig. 6 De-Glazing Drill Speed and Vertical Speed
CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi­
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 7).
1st REFACE
0.25 mm (0.0098 inch)
2nd
REFACE
0.25 mm (0.0098 inch)
®
Total
0.50 mm (0.0197 inch)
® Standard
323.00 mm ±0.10 mm
(12.7165 inch ±0.0039 inch)
1st REFACE 3 2 2 . 7 5 mm ±0.10 mm
(12.7067 inch ±0.0039 inch)
2nd REFACE
322.50 mm ±0.10 mm
(12.6968 inch ±0.0039 inch)
J9409-123
Fig. 7 Refacing Dimensions of the Cylinder Block
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 8),
Fig. 8 Stamp Block after Reface
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
CYLINDER BORE REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
• Method 1:—Over boring and using oversize pistons
and rings.
• Method 2:—Boring and installing a repair sleeve
to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 9). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 9).
A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 10). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maximum of 1.2 micrometer (48 microinch) sur­
face 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.