Dodge Ram Truck 1500-2500-3500. Manual — part 1416

5. A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles. For the rough

hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.

6. 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.

7. The crosshatch angle is a function of drill speed

and how fast the hone is moved vertically.

8. Vertical

strokes

MUST be

smooth

continuous

passes along the full length of the bore.

9. Inspect the bore after 10 strokes.

10. Use a strong solution of hot water and laundry

detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.

11. Rinse the bores until the detergent is removed

and blow the block dry with compressed air.

12. Check the bore cleanliness by wiping with a

white, lint free, lightly oiled cloth. If grit residue is
still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete block
assembly with solvent and dry with compressed air. Place a clean shop towel around the top main bearing
saddle to deflect water and residue from piston cooling nozzels. Remove directed piston cooling nozzles if
installed.

13. Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning

process is complete.

STANDARD PROCEDURE—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

Cylinder bore(s) can be repaired by one of two methods:

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. 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.

CYLINDER BORE DIMENSION CHART

DESCRIPTION

MEASUREMENT

BORING DIAMETER DIMENSION

1st. REBORE - 102.469 mm (4.0342 in.)

2nd. REBORE - 102.969 mm (4.0539 in.)

HONING DIAMETER DIMENSIONS

STANDARD - 102.020 ± 0.020 mm (4.0165 ± 0.0008 in.)

1st. REBORE - 102.520 ± 0.020 mm (4.0362 ± 0.0008 in.)

2nd. REBORE - 103.020 ± 0.020 mm 4.0559 ± 0.0008 in.)

CHAMFER DIMENSIONS

Approx. 1.25 mm (0.049 in.) by 30°

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A correctly honed surface will have a crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit hon-
ing stones.

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 deter-
gent and hot water.

After rinsing, blow the block dry.

Check the bore cleanliness by wiping with a white, lint-free, lightly- oiled cloth. There should be no grit residue
present.

If the block is not to be used right away, coat it with a rust- preventing compound.

METHOD 2—REPAIR SLEEVE

REPAIR SLEEVE BLOCK REBORE DIMENSIONS CHART

BORE DIAMETER

STEP DIMENSION

104.500 + 0.015 mm (4.1142 + 0.0006 in.)

6.35 mm (0.25 in.)

If more than a 1.00 mm (0.03937 inch) diameter oversize bore is required, the block must be bored and a repair
sleeve installed.

Bore the block cylinder bore to 104.500-104.515 mm (4.1142-4.1148 inch).

Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. DO NOT cut the cylinder bore
beyond the oversize limit.

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After machining the block for the new repair sleeve,
thoroughly clean the bore of all metal chips, debris
and oil residue before installing the sleeve.

Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it from
the freezer.

Apply a coat of Loctite 620, or equivalent to the bore
that is to be sleeved.

Wear protective gloves to push the cold sleeve into
the bore as far as possible.

Using a sleeve driver (1), drive the sleeve (2) down-
ward until it contacts the step at the bottom of the
bore.

SLEEVE DRIVER CONSTRUCTION SPECIFICATION CHART

ITEM

MEASUREMENT

A

127 mm (5 in.)

B

38 mm (1.5 in.)

C

6.35 mm (0.25 in.)

D

25.4 mm (1 in.)

E

101 mm (3.976 in.)

F

107.343 mm (4.226 in.)

A sleeve driver can be constructed as shown.

SLEEVE MACHINING DIMENSIONS CHART

ITEM

MEASUREMENT

SLEEVE PROTRUSION

MIN. - FLUSH WITH BLOCK

MAX. - 0.050 mm (0.0019 in.)

SLEEVE DIAMETER

101.956 mm (4.014 in.)

SLEEVE CHAMFER

APPROX. 1.25 mm (0.049 in.) by 15°

Set up a boring bar and machine the sleeve to 101.956 mm (4.014 inch).

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After removing the boring bar, use a honing stone to chamfer the corner of the repair sleeve(s).

A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the
cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.

Finished bore inside dimension is 102.020 ±0.020 mm (4.0165 ±0.0008 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.

Wipe the bore with a white, lint-free, lightly oiled cloth. Make sure there is no grit residue present.

Apply a rust-preventing compound if the block will not be used immediately.

A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore.

STANDARD PROCEDURE - CAM BORE REPAIR

For standard bushings, not oversized, maximum front
cam bushing bore diameter is 59.248 mm. (2.3326
in.). DO NOT bore the intermediate cam bore to the
front cam bore oversize dimensions. Maximum front
camshaft bushing installed diameter is 54.147 mm.
(2.1318 in.). Minimum installed diameter is 54.083
mm. (2.1293 in.). Maximum intermediate camshaft
bore diameter is 54.164 mm. (2.1324 in.).

A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area of
any one bore may be 3.2 micrometers (126 micro-
inch).

Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair
individually damaged cam bores. The standard front bushing (1) cannot be used to repair intermediate bores.

Install all cam bushings flush or below the front and rear cam bore surface. The front camshaft bushing should be
installed flush with front face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through
freely.

INSPECTION

Measure the combustion deck face using a straight
edge (1) and a feeler gauge (2). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum vari-
ation side-to-side 0.051 mm (.002 in.).

Inspect for any localized dips or imperfections.

If the surface exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).

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