Alternative Repair Procedures
PageiK-6
Base
Engine Components
DODGE
Turbo Diesel
Cylinder Bore(s)
Block
cylinder bores may be rebored twice before use of a
repair sleeve is required. The first rebore is
0.50mm
[0.197
inch]
oversize. The second rebore is
1.00mm[0,0393
inch]
oversize.
Boring Diameter Dimensions
A
=
102.469mm
[4.0342
inch]
102.969mm
[4.0539
inch]
Honing Diameter Dimensions
First
rebore
Second
rebore
B
»
102.020
±
.020mm
Standard bore
[4.0165
±.0008 inch]
102.520
±
.020mm
First rebore
[4.0362
±.008 Inch]
103.020
±
.020mm
Second rebore
[4.0559
±.0008 inch]
After
boring to
size,
use
a honing stone to chamfer the edge of the
bore to Dimension C.
Approximately
1.25mm
[.049 inch] X 15 Degrees
A
correctly honed surface
will
have a
cross-hatch
appearance
wm/
with
the lines at 15 to 25 degree angles
with
the top of the
5n cylinder block.
Rough hone: Use 80
grit
honing stones.
Finish
hone: Use 280
grit
honing stones.
A
maximum of 1.2 micrometer [48 microinch] surface finish
must be obtained.
VI
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.
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