SAFARI

ENGINE

Fig. 8

Fig. 7

MAIN BEARING CAP

BOLT

TUBE

3 Do not smear parent bore or liner outer diameter

with oil.

4 Place liner in parent bore and make it at right

angles to cylinder block surface in longitudinal and

perpendicular planes using precision tri-square.

5 Press liner using drift, 2651 5890 02 02 ensuring

that ram is seating squarely on the drift.

Note: Fully pressed in liner protrudes beyond block

face by 0.5 to 0.6 mm. Utmost care should be

exercised at the end of liner pressing. To make sure

that the liner is pressed fully home, load should be

applied very carefully with fine increments.

Subjecting liner under high pressure at this stage

may result in cracking of the liner at the collar.

6 Similarly press all remaining liners.

CYLINDER BORE MACHINING

1 Machine all bores to 96.93 to 96.95 mm dia.

leaving 0.05 to 0.07 mm stock for honing.

2 Using a face cutter tool, machine off protrusion of

liner to make it flush with the block surface.

Machine a chamber of 0.5 mm x 45 deg on I.D. of

the liners.

The honing should be done in two stages as

follows:

Stage I

Use honing stone of grit 180. The honing speed

should be approx. 100-120 rpm and approx. 60

double strokes per minute and length of stroke

130 mm. Under these conditions, a cross hatch

angle E of approx. 45 to 60 deg is obtained.

Leave only 0.01 mm material for the 2nd stage

honing.

Stage II

In the 2nd stage of honing, use honing stone of

grit 240. The honing speed should be approx.

50-60 rpm, with 30 double strokes per minute and

130 mm stroke length.

With this, a cross hatch angle of approx. 45 deg

to 60 deg is obtained.

NOTE

It is very important that the axis of the cylinder

bores are parallel to each other and are at right

angles to axis of crankshaft. Therefore, we

recommend the use of pillar type boring and

honing machines in preference to portable type

boring bar and honing machines. If the portable

boring bar must be used, check and clean mating

surface of the boring bar and cylinder block, and

centralise the boring bar as accurately as possible.

2 Clean cylinder block thoroughly and apply grease

on machined surfaces of cylinder block especially

if the engine assembly is not to be taken up

immediately.

Adjust hone travel to ensure that the honing tool

projects by approx 20-25 mm from the top and

bottom during honing. Use plenty of kerosene for

this operation.

v. OIL PASSAGES

1 Clean all oil passages thoroughly by using suitable

wire brushes/compressed air.

2 Tubes shown in Fig. 7 prevent leakage of engine

oil through main bearing bolts or oil passage to

main oil gallery.

If necessary, new tubes may be fitted with the

drift as shown in the Fig. 8.