Chrysler 1991 Service Manual Supplement page 81

9 - 18 5.91. (DIESEL) ENGINES
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Measure the cylinder bores (Fig. 8). Do not proceed
with in-chassis repair if the bores are damaged or
worn beyond the limits (refer to Cylinder Bore Re-
pair - Cylinder Block).
MIN. 102.0 m m (4.0157 inch)
MAX. 102.1 16 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. 8 Cylinder Bore Diameter
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero-
sion, etc.
Check the head distortion (Fig. 9). 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).
Do not proceed with the in-chassis overhaul i f the
cylinder head or block surface is damaged or not flat
(within specifications).
Fig. 9 Cylinder Head Combustion Deck Face
Measurement
REFACINQ HEm 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 just
above the edge of the combustion deck on the lower
right hand corner of the rear face (Fig. 10). Check
valve protrusion 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. 10 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.
(2) Position the gasket onto the dowels (Fig. 11).
Make sure the gasket is correctly aligned with the
holes in the cylinder block.
(3) Carefully put the cylinder head onto the gasket
and cylinder block. Make sure the cylinder head is
installed onto the dowels in the cylinder block (Fig.
11).
(4) Install the push rods and rocker levers.