roof DODGE RAM 2001 Service User Guide

is in place to avoid scratching the roof panel. Using a
slow, back-and-forth sweeping motion, and allowing
13 millimeters (0.50 inch) between passes, move the
tool at least 11 centimeters (4 inches) to each side of
the roof center line, and 28 centimeters (11 inches)
back from the windshield header.
(10) With the degaussing tool still energized,
slowly back it away from the roof panel. When the
tip of the tool is at least 61 centimeters (2 feet) from
the roof panel, disconnect the tool.
(11) Calibrate the compass and adjust the compass
variance. Refer toCompass Variation Adjustment
andCompass Calibrationin the Standard Proce-
dures section of this group for the procedures.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the garage door opener storage bin door
and locate the two overhead console latch tabs near
the front of the bin (Fig. 4).
(3) While pulling gently downward on the front of
the overhead console, push the latch tabs forward
until each latch is disengaged from its receptacle in
the inner roof panel.(4) Slide the overhead console rearward far enough
to disengage the two mounting hooks on the rear of
the housing from the mounting holes in the inner
roof panel (Fig. 5).
(5) Lower the overhead console from the headliner
far enough to access the wire harness connector.
(6) Disconnect the roof wire harness connector
from the overhead console wire harness connector.
Fig. 3 Roof Demagnetizing Pattern
Fig. 4 Overhead Console Latch Tabs
1 - PUSH BUTTON
2 - GARAGE DOOR OPENER STORAGE BIN DOOR
3 - LATCH TABS
Fig. 5 Overhead Console Remove/Install
1 - HEADLINER
2 - MOUNTING HOOKS
3 - OVERHEAD CONSOLE
4 - GARAGE DOOR OPENER STORAGE BIN DOOR
5 - WIRE HARNESS CONNECTOR
6 - INNER ROOF PANEL
8M - 6 MESSAGE SYSTEMSBR/BE
OVERHEAD CONSOLE (Continued)

the latch. Repeat this step to engage the second pivot
pin with its pivot latch.
(3) Close the garage door opener storage bin door.
(4) If the vehicle is so equipped, position the com-
pass mini-trip computer module to the back side of
the overhead console housing. Install and tighten the
three screws that secure the module to the housing.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Install the overhead console onto the headliner.
Refer toOverhead Consolein the Removal and
Installation section of this group for the procedures.
SUNGLASS STORAGE BIN
(1) From the face side of the overhead console
housing, position the sunglasses storage bin pivot
arms through the openings in the front of the storage
bin housing in the overhead console.
(2) From the back side of the of the overhead con-
sole housing, align one of the pivot pins of the sun-
glasses storage bin with the pivot latch integral to
the overhead console housing. Press the pivot arm
forward until the pivot pin is engaged in the latch.
Repeat this step to engage the second pivot pin with
its pivot latch.
(3) Close the sunglasses storage bin.
(4) Position the reading and courtesy lamp housing
to the back side of the overhead console housing.
Install and tighten the four screws that secure the
lamp housing to the back of the overhead console
housing. Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Install the overhead console onto the headliner.
Refer toOverhead Consolein the Removal and
Installation section of this group for the procedures.
MINI-TRIP COMPUTER LENS
Overhead consoles equipped with the optional com-
pass mini-trip computer have a lens installed in the
front of the overhead console housing through which
the Vacuum-Fluorescent Display can be viewed. If
the overhead console is not equipped with the com-
pass mini-trip computer option, a plastic cover plug
is installed in the front of the overhead console hous-
ing in place of the lens.
(1) Remove the trip computer lens or the cover
plug onto the overhead console housing.
(2) From the face of the overhead console, push the
trip computer lens or the cover plug forward far
enough to engage the four forward mounting tabs in
the overhead console unit.
(3) From the face of the overhead console, align
the rear mounting boss of the trip computer lens or
the alignment pin of the cover plug with the recepta-
cle in the overhead console housing.
(4) Press firmly and evenly on the rear edge of the
trip computer lens or the cover plug until the rear
mounting boss is fully seated in the receptacle, or thesnap features of the cover plug are fully engaged in
the overhead console housing.
(5) If the vehicle is so equipped, install the com-
pass mini-trip computer module onto the overhead
console. Refer toCompass Mini-Trip Computerin
the Removal and Installation section of this group for
the procedures.
(6) Install the overhead console onto the headliner.
Refer toOverhead Consolein the Removal and
Installation section of this group for the procedures.
INSTALLATION
(1) Position the overhead console near the mount-
ing location on the headliner in the vehicle.
(2) Reconnect the roof wire harness connector to
the overhead console wire harness connector.
(3) Engage the two mounting hooks on the rear of
the overhead console housing in the mounting holes
in the inner roof panel.
(4) Slide the overhead console forward far enough
to align the two latches on the front of the housing
with their receptacles in the inner roof panel.
(5) Push upward firmly and evenly on the front of
the overhead console until each of the two latches is
fully engaged in its receptacle in the inner roof panel.
(6) Close the garage door opener storage bin door.
(7) Reconnect the battery negative cable.
SPECIAL TOOLS
OVERHEAD CONSOLE SYSTEMS
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The compass mini-trip computer is located in the
premium overhead console on models equipped with
this option. Two compass mini-trip computer units
are available. One unit is used on vehicles not
equipped with the Vehicle Theft Security System
(VTSS) option, and the other is used on vehicles with
the VTSS option. Both compass mini-trip computer
units include the electronic control module, a Vacu-
um-Fluorescent Display (VFD), a compass flux-gate
unit and two push button function switches.
Degaussing Tool 6029
8M - 8 MESSAGE SYSTEMSBR/BE
OVERHEAD CONSOLE (Continued)

DIAGNOSIS & TESTING - COMPASS MINI-TRIP
COMPUTER
If the problem with the compass mini-trip com-
puter module is an inoperative security indicator
lamp, refer toSecurity Indicator Lampin Vehicle
Theft/Security Systems. If the problem with the com-
pass mini-trip computer module is an ªOCº or ªSCº in
the compass/thermometer display, refer toAmbient
Temperature Sensorin the Diagnosis and Testing
section of this group. If the problem with the com-
pass mini-trip computer module is an inaccurate or
scrambled display, refer toSelf-Diagnostic Testin
the Diagnosis and Testing section of this group. If the
problem with the compass mini-trip computer module
is incorrect Vacuum Fluorescent Display (VFD) dim-
ming levels, use a DRBtscan tool and the proper
Diagnostic Procedures manual to test for the correct
dimming message inputs being received from the
instrument cluster over the Chrysler Collision Detec-
tion (CCD) data bus. If the problem is a no-display
condition, use the following procedures. For complete
circuit diagrams, refer toOverhead Consolein the
Contents of Wiring Diagrams.
(1) Check the fused B(+) fuse in the junction block.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the junction block. If OK, go to Step 3. If not OK,
repair the open fused B(+) circuit to the battery as
required.
(3) Check the fused ignition switch output (run/
start) fuse in the junction block. If OK, go to Step 4.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) fuse in the junction block. If OK,
go to Step 5. If not OK, repair the open fused ignition
switch output (run/start) circuit to the ignition switch
as required.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the overhead console. Check for continuity
between the ground circuit cavities of the roof wire
harness connector for the overhead console and a
good ground. There should be continuity. If OK, go to
Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
roof wire harness connector for the overhead console.
If OK, go to Step 7. If not OK, repair the open fused
B(+) circuit to the junction block fuse as required.(7) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the roof wire har-
ness connector for the overhead console. If OK, refer
toSelf-Diagnostic Testin the Diagnosis and Test-
ing section of this group for further diagnosis of the
compass mini-trip computer module and the CCD
data bus. If not OK, repair the open fused ignition
switch output (run/start) circuit to the junction block
fuse as required.
SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the
compass mini-trip computer module is operating
properly electrically. Initiate the self-diagnostic test
as follows:
(1) With the ignition switch in the Off position,
simultaneously depress and hold the Step button and
the U.S./Metric button.
(2) Turn the ignition switch to the On position.
(3) Continue to hold both buttons depressed until
the compass mini-trip computer module enters the
display segment test. In this test, all of the Vacuum
Fluorescent Display (VFD) segments are lighted
while the compass mini-trip computer module per-
forms the following checks:
²Microprocessor RAM read/write test
²Non-volatile memory read/write test
²Microprocessor ROM verification test
²CCD communications test.
(4) Following completion of these tests, the com-
pass mini-trip computer will display one of three
messages: ªPASS,º ªFAIL,º or ªCCd.º Respond to the
respective test results as follows:
²If the ªPASSº message is displayed, but compass
mini-trip computer operation is still improper, the
use of a DRB scan tool and the proper Diagnostic
Procedures manual are required for further diagno-
sis.
²If the ªFAILº message is displayed, the compass
mini-trip computer module is faulty and must be
replaced.
²If the ªCCdº message is displayed, the use of a
DRBtscan tool and the proper Diagnostic Proce-
dures manual are required for further diagnosis.
²If any VFD segment should fail to light during
the display segment test, the compass mini-trip com-
puter module is faulty and must be replaced.
(5) If all tests are passed, or if the ignition switch
is turned to the Off position, the compass mini-trip
computer module will automatically return to normal
operation.
8M - 10 MESSAGE SYSTEMSBR/BE
COMPASS/MINI-TRIP COMPUTER (Continued)

DIAGNOSIS & TESTING - AMBIENT
TEMPERATURE SENSOR
The thermometer function is supported by the
ambient temperature sensor, a wiring circuit, and a
portion of the compass mini-trip computer module. If
any portion of the ambient temperature sensor cir-
cuit fails, the compass/thermometer display function
will self-diagnose the circuit. If 55É C (131É F)
appears in the display, the sensor is being exposed to
temperatures above 55É C (131É F), or the sensor cir-
cuit is shorted. If ±40É C (±40É F) appears in the dis-
play, the sensor is being exposed to temperatures
below ±40É C (±40É F), or the sensor circuit is open.
The ambient temperature sensor circuit can also be
diagnosed using the following Sensor Test, and Sen-
sor Circuit Test. If the temperature sensor and cir-
cuit are confirmed to be OK, but the temperature
display is inoperative or incorrect, refer toCompass
Mini-Trip Computerin the Diagnosis and Testing
section of this group. For complete circuit diagrams,
refer toOverhead Consolein the Contents of Wir-
ing Diagrams.
SENSOR TEST
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector.
(2) Measure the resistance of the ambient temper-
ature sensor. At ±40É C (±40É F), the sensor resis-
tance is 336 kilohms. At 55É C (131É F), the sensor
resistance is 2.488 kilohms. The sensor resistance
should read between these two values. If OK, refer to
Sensor Circuit Testin the Diagnosis and Testing
section of this group. If not OK, replace the faulty
ambient temperature sensor.
SENSOR CIRCUIT TEST
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector and the overhead console wire har-
ness connector.
(2) Connect a jumper wire between the two termi-
nals in the body half of the ambient temperature sen-
sor wire harness connector.
(3) Check for continuity between the sensor return
circuit and the ambient temperature sensor signal
circuit cavities of the roof wire harness overhead con-
sole connector. There should be continuity. If OK, go
to Step 4. If not OK, repair the open sensor return
circuit or ambient temperature sensor signal circuit
to the ambient temperature sensor as required.(4) Remove the jumper wire from the body half of
the ambient temperature sensor wire harness con-
nector. Check for continuity between the sensor
return circuit cavity of the roof wire harness over-
head console connector and a good ground. There
should be no continuity. If OK, go to Step 5. If not
OK, repair the shorted sensor return circuit as
required.
(5) Check for continuity between the ambient tem-
perature sensor signal circuit cavity of the roof wire
harness overhead console connector and a good
ground. There should be no continuity. If OK, refer to
Compass Mini-Trip Computerin the Diagnosis
and Testing section of this group. If not OK, repair
the shorted ambient temperature sensor signal cir-
cuit as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Locate the ambient temperature sensor, on the
underside of the hood near the hood latch striker
(Fig. 8).
(3) Disconnect the wire harness connector from the
ambient temperature sensor connector receptacle.
(4) Remove the one screw that secures the ambient
temperature sensor bracket to the inner hood rein-
forcement.
(5) Remove the ambient temperature sensor from
the inner hood reinforcement.
Fig. 8 Ambient Temperature Sensor Remove/Install
1 - HOOD
2 - SCREW
3 - SENSOR AND BRACKET
4 - WIRE HARNESS CONNECTOR
5 - HOOD LATCH STRIKER
8M - 12 MESSAGE SYSTEMSBR/BE
AMBIENT TEMP SENSOR (Continued)

Splice Number Location Fig.
S301 Body Harness, Left Side Instrument Panel 10
S302 Body Harness, Left Side Instrument Panel 10
S303 Body Harness, Left Side Instrument Panel 10
S304 Body Harness, Left Side Instrument Panel 10
S305 Body Harness, Right Side Instrument Panel N/S
S306 Body Harness, Left Side Instrument Panel 10
S307 Body Harness, Left Cowl 10
S308 Body Harness, Left Cowl 10
S310 At Left Body Ground N/S
S311 At Left Body Ground N/S
S313 Left Rear Frame Rail 11
S314 Left Rear Frame Rail N/S
S315 Left Rear Frame Rail 11
S316 Left Rear Frame Rail 11
S317 Left Rear Frame Rail 11
S318 In T/O to Trailer Tow 11
S319 In T/O to Left Rear Lamps 11
S320 In T/O to Trailer Tow 11
S321 In T/O to Left Rear Lamps 11
S322 Overhead Console Harness, At Roof Lamps 9
S323 Overhead Console Harness, At Roof Lamps 9
S324 Overhead Console Harness, At Roof Lamps 9
S325 Overhead Console Harness, At Roof Lamps 9
S326 Overhead Console Harness, At Roof Lamps 9
S327 Power Seat Harness, Near Switch N/S
S328 Power Seat Harness, Near T/O to Body Wiring N/S
S329 Door Harness, Near Left Door Near Grommet N/S
S330 Door Harness, Near Right Door Near Grommet N/S
S331 Chassis Harness, Near T/O to Fuel Pump Module 11
S332 Body Harness, Left Side Instrument Panel 10
S333 Power Seat Harness, Near T/O to Passenger Seat Jumper N/S
S335 Power Seat harness, Near T/O to Body Wiring N/S
S336 Power Seat Harness, Under Passenger Seat N/S
S337 Power Seat Harness, Under Passenger Seat N/S
S340 Overhead Console Harness, At Roof Lamps 9
S401 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Left Back-up Lamp N/S
S402 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Right Back-up Lamp N/S
S404 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
S406 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
BR/BE8W-95 SPLICE LOCATIONS 8W - 95 - 3
SPLICE LOCATIONS (Continued)

(3) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket and crossÐover gaskets (Fig. 68).
The sealant should be approximately 5 mm (0.2 in)
in diameter.
(4) Install the front and rear cross-over gaskets.
(5) Using a new gasket, install the throttle body
onto the intake manifold (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/THROTTLE BODY -
INSTALLATION).
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Install the intake manifold bolts and tighten as
follows (Fig. 70):
²Step 1. Tighten bolts 1 and 2 to 8 N´m (72 in.
lbs.) Tighten in alternating steps 1.4 N´m (12 in. lbs.)
at a time
²Step 2. Tighten bolts 3 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
Fig. 68 Cross-Over Gaskets
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 69 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 70 Intake Manifold Bolt Tightening Sequence
9 - 54 ENGINE 3.9LBR/BE
INTAKE MANIFOLD (Continued)

INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 66).
(2) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 68). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter.
(5) Install the front and rear cross-over gaskets
(Fig. 67).
(6) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(7) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
Fig. 66 Plenum Pan Bolt Tightening Sequence
Fig. 67 Cross-Over Gaskets
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 68 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
BR/BEENGINE 5.2L 9 - 111
INTAKE MANIFOLD (Continued)

(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 68). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15mm (0.6 in.)
long.
(5) Install the front and rear end seals (Fig. 67).
Make sure the molded dowel pins on the end seals
fully enter the corresponding holes in the cylinder
block.
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(8) Install the intake manifold bolts and tighten as
follows (Fig. 69):
²Step 1. Tighten bolts 1 through 4 to 8 N´m (72
in. lbs.) Tighten in alternating steps 1.4 N´m (12 in.
lbs.) at a time²Step 2. Tighten bolts 5 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
Fig. 67 Front and Rear End Seals
1 - FRONT END SEAL
2 - REAR END SEAL
Fig. 68 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 69 Intake Manifold Bolt Tightening Sequence
BR/BEENGINE 5.9L 9 - 167
INTAKE MANIFOLD (Continued)

(6) Remove the air cleaner cover and filter.
Remove the air cleaner housing (Fig. 70). Discard the
gasket.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove the coil assemblies with the ignition
wires.
(10) Disconnect the vacuum lines.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove the throttle body bolts and lift the
throttle body off the upper intake manifold (Fig. 71).
Discard the gasket.
(14) Remove upper intake manifold bolts.
(15) Lift the upper intake manifold out of the
engine compartment (Fig. 71). Discard the gasket.
(16) Remove the lower intake manifold bolts and
remove the manifold (Fig. 72).
(17) Discard the lower intake manifold gaskets
(Fig. 73).
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install the intake manifold side gaskets. Be
sure that the locator dowels are positioned in the
head (Fig. 74).
(2) Insert MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, into the four corner joints
an excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in.) in diameter. (Fig. 73).
Fig. 70 Air Intake Housing
1 - AIR INTAKE HOUSING
Fig. 71 Upper Intake Manifold and Throttle Body
1 - UPPER INTAKE MANIFOLD
2 - THROTTLE BODY (MPI)
3 - LOWER INTAKE MANIFOLD
Fig. 72 Lower Intake Manifold
BR/BEENGINE 8.0L 9 - 223
INTAKE MANIFOLD (Continued)

(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. 69).
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
STANDARD PROCEDURE-CYLINDER BORE -
DE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der 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 in the top of the block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hatch appearance with the lines at 15É to 25É angles
(Fig. 70). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(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 crosshatch angle is a function of drill speed
and how fast the hone is moved vertically (Fig. 71).
(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 71).
(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.
Fig. 68 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm  
0.10 mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm  
0.10 mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm  
0.10 mm(12.6968 in.  
0.0039 in.)
Fig. 69 Stamp Block after Reface
Fig. 70 Cylinder Bore Crosshatch Pattern
Fig. 71 De-Glazing Drill Speed and Vertical Speed
9 - 264 ENGINE 5.9L DIESELBR/BE
ENGINE BLOCK (Continued)